Prepping and Priming Some Rear Spar Components

November 20, 2010

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Oh man, I’m furious. I just spent some time doing a huge writeup for this post, and when I clicked, “Post”, it deleted all of my text.


I’ll try to rewrite it, but it is going to have a little bit of an annoying tone.

Anyway, I managed to get out in the shop today for a little. I had previously gotten all of the doubler plates and reinforcement forks matchdrilled to the spar, so today was all about prepping and priming.

Here’s W-707F, which sits on the back side of the left spar. I’ve deburred and scuffed it; all I need to do now is dimpled the outboard holes in preparation for attaching it to the spar and outboardmost rib.

I love scuffed parts. They hide my fingerprints.

Here’s W-707E, which is the doubler plate that sits on the aft side of the rear spar, right in the middle. I’ve marked the cutout for the aileron push tube. Where’s that step drill?

Yup, here you can see my fingerprints.

I started looking around for my stepdrill. I spent good money on that stepdrill, but I couldn’t find it anywhere. On the workbench, under the workbench, on the floor, in some other shelves. I thought maybe I put it in some other tool’s case, so I got out the dremel tool, multifunction tool, jig saw, circular saw, etc. Nothing.

I even accused the girlfriend of selling it on the black market to fund an bottle of Opus One. She insisted that while she thought about it, she didn’t.

I remember putting it in this old small cabinet of drawers (that my dad gave me when I graduated college…thanks, dad!). I spent about 30 minutes just pulling out each one of these drawers, looking for my step-drill. Grrr.

After continuing to work on the airplane (angrily) for another 30 minutes, I finally found it when I came back to the drawers and opened them with my other hand. Apparently my sausage fingers (they’re not, I promise…I’m just mad) blocked my view of the stepdrill, which was right behind the lip of the VERY FIRST DRAWER.


Anyway. Back to the rear spar. This is the forward side of the left spar, outboard end. I’ve deburred the edges of the whole spar, and now I’m deburring all of the holes I drilled.

I always scuff the areas where there are holes I've drilled and deburred. Helps me keep the "did I do this already" time to a minimum.

Oh yeah, I managed to get a couple parts primed today. Like riveting, I always feel like it is a productive day if I can prime some things.

You can also see my primer of choice, Napa 7220.

Here’s the other side of those pieces (after plenty of drying time).

I like priming.

Back to the spar, more deburring holes and scuffing.

I'll finish scuffing the whole spar when I get closer to priming.

This is the middle of the rear spar, around the aileron pushtube hole. More deburring and scuffing.

Jeesh, there are fingerprints everywhere.

Finally, I brought the two primed parts back inside.

Primed parts on the workbench always means we're getting close to riveting. Wuhoo!

After this was about when I finally found my step-drill. I was too angry at myself to keep going, so I headed inside to some grilled chicken, jasmine rice, and creamed corn. Mmmm.

1.5 hours

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Tank Attach Nutplates, Left Lower Spar Flange

October 21, 2010

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With the girlfriend gone for the night, I managed to clean up all of the electrical stuff I had out messing around with my wig-wag experiment, and pulled the left spar out of the box. Here it is, in all of it’s golden glory.

Golden Glory!

First step is to countersink the tank (and access plate) nutplate attach holes. First, you have to run a #40 drill through the holes or else the countersink pilot won’t even fit in the hole. Here’s one of my first countersinks on the left spar.

I went back and cleaned this one up after testing with a AN426AD3-11 rivet (-11 because it's easier to get back out while testing's so long you can just push it back out from the back.)

These countersinks are a little better. (The one on the right is a tad deep, but should be okay because these are just nutplate attach holes.)

I left the door to the house open so the pups could come out to visit.

Hey guys (Jack and Ginger).

Hey Andrew, how about one of those artsy shots down the spar after countersinking the nutplate attach holes?

Sure, here you go.

Then, I pulled the K1100-08 nutplates out for the tank attach holes and the K1000-06 nutplates out for the access plate holes, then clecoed one side in, and put the required rivet (AN426AD3-4) in the holes.

Where’s my squeezer?

It's right there on the table, dummy.

Then I squeezed some rivets and removed the clecos.

Squeezed (repeated 41 more times.)

Other side done. (Repeated 41 more times.)

Under the hood, things look good. I still like this new Cleveland main squeeze much better than my economy squeezer.

Pretty shop heads.

Down the row.

I then laid the spar down and saw this guy.


Whoa. Scary.

After a little internet research, I think I’ve figured out he (actually she due to her size) is a red-back.  I’m going to keep looking though. I don’t want it to be a red-back.

1.0 hour. 84 rivets.

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