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Terrences Web Site
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Date: 3-23-2010
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Number of Hours: 3.00
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Manual Reference: N/A
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Brief Description: Cut off spar cap angle and clean up spar cap
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1. Per the Photoguide, cut a V-notch in the spar cap angle at the 1680 location (I actually cut at 1681 mm.).
2. Slide a small piece of 0.016 aluminum between the spar cap angle and the spar cap, see Fig. 1.
3. Cut the rest of the spar cap angle off with a hack saw, being careful to not damage any other part of the spar structure.
4. Use a file to smooth the end edges of the spar cap angle.
5. Before I could position the new spar cap extrusion onto the spar cap, I needed to remove the remains of a couple of rivets from the spar cap and to deburr the holes (see Figs. 2 & 3):
6. Starting with a #23 drill bit, followed by a #22, then a #21, etc., I slowly enlarged the hole through the center of the rivet, taking care to hold the drill normal to the spar cap. When I got to a #10, the rivets were mostly gone. I carefully picked out a small amount of residual rivet material from one of the holes with a scribe.
7. After drilling out the rivet material I used my stub file deburring tool to smooth the rear face of the spar cap at the two holes and near one or two other holes, so that The spar cap was smooth. I also removed a couple of burrs from the web.
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Spar cap angle notch & cut line
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Mucked up rivet remains_1
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Mucked up rivet remains_2
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