Short, but productive day.
It was Jack’s birthday today (he turned 3), so I ran out to Chik-Fil-A to get him is once a year human food treat. A chicken biscuit. Of course, Ginger needed one too (“so she doesn’t feel left out”) and so on, which meant my girlfriend and I also got biscuits. Here are Jack and Ginger.
Anyway, after the birthday festivities (a.k.a. Jack and Ginger inhaling their biscuits), I managed a couple hours on the project. Here, I clamped HS-404 in place after having first marked holes and drilled #40 pilot holes in the aft flange. The instructions have you mark and drill pilot holes in the HS-405, but why drill from aft to forward, hoping you don’t run into edge distance problems when you could drill from forward to aft? For the outboard holes, I did use the HS-405 for pilot holes. You’ll see.
Here are the silver clecos after drilling from forward to aft with my 12″ bit.
Then, I used the previously marked and pilot drilled holes in HS-405 to drill forward through the HS-702 (front spar) and HS-710/714 (reinforcement angles). The 12″ bit really came in handy here.
Then, I matchdrilled the rest of the HS-404, which had been clamped in place in the above pictures. After that, I finished match-drilling the rest of the skin for the right side. After you finish and pull the skin off, you can drill the remaining HS-702 holes using the HS-710 and HS-714 angles as guides. Here are the last six holes drilled after pulling off the skin.
After the skins are pulled off, I’m ready to start prep for final assembly.