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First thing in the morning, I had to run some errands, one of which included a stop by Harbor Freight to exchange my Automatic Compressor Drain Kit that had a crack in it. While I was there, I used two coupons. One, for a free tape measure, the other for almost half off a 6″ digital caliper. Walked out the door with a new caliper, tape measure, and an exchanged drain kit for $10. Can’t beat that.
Free tape measure at Harbor Freight. Also a coupon for 1/2 off a $20 digital caliper.
I went ahead and scotchbrited all the HS ribs. I was sick of the aluminum dust on my hands during scotchbriting, so I took these inside and did them with warm water (only reason for warm was so my hands didn’t get cold) in the kitchen sink. Worked well with a lot less dust. (Also, I think showing pictures of my work with finished pieces looks a lot better than the original parts, which are all shiny and finger-printy after my grubby hands work with them.)
Surface prepped HS ribs.
Then, the directions have you cleco the left skeleton together.
It looks like an airplane! Kind of.
I did the right side too (mostly so I could take the next picture), then match-drilled all of the rib/spar attach points to #30, (except for 708/603), which they have you do later to a #21.
Both skeletons after match-drilling all of the rib to spar attach points.
Then you get to cleco on the skin (wuhoo!). I had trouble with HS-707 here. the very tip of the rib kind of caught on the skin (vinyl); I had to really work to get it back into position and clecoed. you can see here I clecoed every hole on the HS-707.
Clecoed on the left HS-601 skin.
Then I inserted the HS-404 (front inboard) and HS-405 (rear inboard) ribs and clamp. Here, you can see the HS-405 clamped.
Inserted HS-404 and HS-405 for match drilling.
Then I match-drilled the HS-405 to the HS-601PP (skin). I didn’t do the top or bottom forward most hole, because I seem to be having edge distance troubles on the HS-405 and HS-702 spar. I checked everything and it seems to be right. I checked some other build sites to see if other people have run into this, no one mentioned it. Right as I was going to post a question on the VAF forums about this, a new thread popped up. Apparently this is a common problem, and the edge distance on HS-405 is not to be worried about. It’s a little confusing, though, given the prepunched nature of the parts.
I went ahead and match-drilled it. I’ll examine the edge distance a little more closely when I take apart the HS for prep. I repeated all the steps for the right side, then started in on match-drilling the skin to forward spar holes inboard of the 707. (Below, you are looking at the bottom of the stab, so the right HS is on the left in the picture. you can see the extra clecos from what I will call the “middle ribs” (708 and 707) inboard along the front spar. Those are not pre-punched on the spar, so you have to use the holes in the skin to match-drill.)
Then repeated for the right HS. Looks like an airplane!
11am to 6pm, with an hour for lunch. 6 hours today.
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Posted by Andrew 
Andrew's RV-7 Build Log 