I have been working the past three days taking one side apart at a time and deburring every hole in the skins, bulk heads and longerons. This is a time consuming process but using my little electric screw driver with a deburring bit from Avery tools makes the job much easier than using the twirly deburring tool. After the plastic was removed from the side skins and all of the holes deburred, it was time to bend the front edge 7 degrees inward. This makes a better fit with the forward fuselage cage skins. Look closely at the third picture and you can see the bend in the right side skin. I bought the bench brake shown in the second picture back in 1999 when I built my first Sonex. I have used it a lot since then. Kinda pricey but makes nice crisp bends in aluminum up to .040 gauge. You can see my set up using a folding chair and a couple of 1" X 4" boards to hold the long skin level during the bending process. If you look closely you can see the small c-clamps I use to hold the skin and bar in place.
The third picture is the right side ready for riveting. I will wait until I get the entire aft fueslage clecoed in place before doing that.
