I located the spar for the stabilizer as required in the blueprints, and began the process of drilling and clecoing the top of the airfoil to the tube. This was an easier process, but still time consuming.
Riveting the trailing edge was simple because access was great. The riveting of the tube spar turned out to be a nightmare. I bought several different shapes and thicknesses of steel to use as bucking bars, but each rivet became more difficult than the last. It was horrible, and it made me seriously doubt my riveting abilities.
With that crap past me, I focused on the outside end cap design. I ended up making a long insert and pop riveting the pieces in place. I kick around making the end cap removable, but decided that I’m going to use my camera probe for inspection, and I wouldn’t really be gaining anything significant by using nut plates. I can always change my mind, but I think it’s okay since the other side is open and accessible.
