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Looking good Bryan. Did you up size the wing blocks all the way?

Not yet Ken but I will. I drilled the blocks by themselves in a drill press vice. Adam did a couple of them the same way. I figure before I drill up I need to figure how to clamp the whole spar on the drill press table. Thanks also Michael, Ken and John for the encouragement.

I drilled the three 1/4" holes in the spar. I used an egg cup drill bushing holder to get to 3/16" but did not have a 1/4" bushing. I drilled three through holes in a bar to 3/16" diameter. Then I drilled most of the way down with a 1/4" bit.


Next I located the block with a 3/16" bit (which is why I didn't go all the way with the 1/4"), clamped in place, and drilled. The block guides the drill.


Obviously I pulled the 3/16" bit out after I clamped it down.

Got my spars rigged up in my drill press. Used my truck canoe rack, plus a step stool, wood blocks, and a bottle jack since I had to offset it.


My last pass was with a .3725 reamer. Had to gently tap the bolt in. Success! Halfway done, left side is still 3/16".

Way to go Bryan. That's why I enjoy the building process, you get to devise all sorts of ways to jig up a part to perform an operation.

David

Thanks David!

To check for trueness, I did 3 things. Check for square on one axis:


Then the other:


Note I used a reject wing block to help. Remember what I said about allowing for saw kerf? The third check is the 3/16" bit I used to drill the blocks should go in and out without binding.

Here is a super-interesting video of me drilling up the blocks on the left side:
http://www.youtube.com/watch?v=a5nJ0gXonHk

Maybe not that interesting. But I will point out the box holding the camera has my new Gaugepod wingtip light mounts. I haven't opened it yet.

I can push both bolts about halfway in by hand with light oil on them. Then I have to tap them in with the little plastic hammer. I am very pleased.

Good video Bryan. Others will learn by it. You will like the Gaugepods, they are well made. I have them on my Onex.

David

Root rib angles:


I am waiting for new, shorter flush bolts to come for the spar mount angles. The specified lengths were very long.

Adam set his first 11 real AN470AD5 rivets today. We practiced on scrap first.
http://youtu.be/tNlD0cddsKM

Some of you may wonder why 11- he smiled one up real good and we had to drill it out. Perfect. You can't really learn to rivet unless you make mistakes. Probably true for anything worth learning. I tried to teach that lesson on the scrap but a real experience is better.

The 10 keepers are awesome.

Adam's riveted stiffener and some spacers. I was trying to transfer holes from the web to the spacers but it was a bear to clamp. Ruined one spacer. Then I thought to make a mild steel tool, which you can see in the picture. I will try it out another day.