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My Airplane Projects
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Date: 3-30-2009
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Number of Hours: 6.00
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Manual Reference: 15-04
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Brief Description: Deburred rib holes, test assembled wing skeleton.
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Spent most of the day deburring lightening holes in wing ribs (174 of them.) This has to be one of the most tedious jobs in the whole project. The burrs on these holes seem to be some of the worst. In some cases very rough. I developed a routine using three power tools - see pictures. The 8" Scotchbrite wheel is now about 4.5 inches, and works good for knocking off the shearing burr on the edge of the hole. I used a 1" sanding tube that just fits over a 1" Scotchbrite wheel in the drill press to remove the bigger irregularities in the surface. Then polished the surface up with one of the 1" wheels mounted on an electric drill clamped in the bench vise. I invented a method of recovering the "slices" of 1" wheel that result from the grooves being cut into the wheels. I just compress them on a bolt between two washers and reuse them. Deburred all the ribs this way. Still have to deburr the little slots in the ribs, and prime them.
After completing the hole deburring I attached all the ribs temporarily to the left wing main spar to check for fit, and to confirm that I trimmed the right number of each configuration. Then I checked the remaining ribs against the instructions for the right wing, stacked them in order of future use, and stored them away. Thank God, everything worked out as planned! Pictures of the temporarily assembled wing in tomorrow's report.
Next: Number all the ribs so they can go back to the right places, remove, deburr, and prime.
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Knock off the burrs.
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Sand off the big bumps.
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Polish it smooth.
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