Brief Description: Flanged and marked left outboard spar web
Two nearly solid weeks of travel have kept me from making progress in the shop...but not in my mental preparation. I've been studying the plans for 6W3 (Outboard Wing Spar Assembly) regularly and asking a lot of questions of Debo Cox and Dave Clay (thanks, guys). My first decision was to bend the outboard end flanges first, giving me an accurate means of measuring the overall length. With my bend calculator I probably could have added the flange at the end to make handling the pieces a little easier, but my plan is to put the two pre-flanged spar webs back-to-back, extend the bottom-facing flange over the edge of the work table by just a few millimeters and then match drill the webs. Debo was kind enough to tell me that there was a measurement error on the plans, but he didn't remember where it was. That sent me on a "Where's Waldo" search, but I finally found the error in the top right drawing on page 6W3. The plans say that the distance between the top and bottom rivet lines for all ribs and ribs angles is 121. The correct answer is 112. I then marked rivet reference lines at 19mm and 31mm from each long side. I then cut the angle on my inboard end and lined it up with the edge of my worktable. That allowed me to hook my metric tape measure over the end of the table for all measurements from the zero reference point on the inboard end. From that point on it was simple math. Just watching my measurements carefully and always rechecking my work. It took longer than I expected, but I am comfortable that I've laid things out correctly. After lunch I'll do one last quick re-check and then get on with pre-drilling 264 holes!
