23/03/2008 - Rear Spar work

In the morning I repeated the steps I made yesterday to rivet and bolt the other tie down together to the spar.  Then I sorted out my CDI torque wrench and nipped everything up to 20-25 in/lbs and torque sealed it all.

Its worth noting I made use of Duralac where different metals touch and I lightly lubricated the bolts before insertion (ooh err missus).  Where I had used the spar holes for match drilling I made sure I re-allocromed (if thats a word!) the holes for protection.

Back to the rear spars.  As well as the doublers mentioned the other day; there are doublers where the ailerons attach onto.  They are just plane pieces of L shaped aluminium as can be seen in picture 4 below.  The middle doubler needs to have an odd hole cut into it to allow the push rods through.  The rear spar is already cut to the shape you just have to cut another one to match.  The Unibit, plus other drills and a nibbler gets a rough cut out about 1/8th from the line all the way round.  Then with files, sweat, and emery cloth the rest is whittled down.  Once more or less there, I switched to the Dremel with the two plates locked together and smoothed all the rough bits out.

All the holes were match drilled #40

The end plate was easier; just match drilling....for now!