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Date:  11-30-2012
Number of Hours:  4.00
Manual Reference:  
Brief Description:  Prepare doubler for right wing spar

Prepare doubler for right wing spar

As noted previously, while working on the wing spar upgrade, I damaged the web of both wing spars. One suggested solution was to add a doubler that would be riveted to the web and then joggled so that it could be riveted to the spar caps. The problem is that I was not confident of bending the 0.040" thick doubler for the joggle. I took the spars over to Helena on 10/17 so that I could discuss the repair with EAA Technical Counselor, Clayton Wilhelm. Clayton suggested that I avoid the joggle by just putting a 0.25" shim between the web and the doubler. What a great idea!

1. A week ago I began implementing the repair on the right spar by cutting the shims from a 0.25" thick 6061 aluminum bar. The shims were 25x135 mm. After sawing them with my skill saw, I filed the edges smooth.

2. For the doubler I decided to use a piece of 0.040 6061T6 that was already cut to 200x100-mm. There was plenty of edge distance for the rivet holes through the spar caps.

3. I clamped the shims in place to the front of the spar web and marked the shims with the location of the holes that I had drilled per Zenair's suggestion back in June 2010. I drilled the marked holes 3/32" & 1/8" on the drill press. Then I clecoed the shims to the web and enlarged the holes to #20 for 5/32 rivets, carefully matching the existing holes in the web. See Fig. 1.

4. I clamped the doubler to the spar & drilled (3/32", 1/8", & #20) opposite corner holes through the existing web rivet holes. Then I clecoed and drilled the remaining web rivet holes through the doubler.

5. Finally, I drilled (3/32, 1/8", & 3/16") holes through the doubler matching the existing rivet holes in the spar caps. See Fig. 2
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Shims clecoed to web

Shims clecoed to web

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Shims and doubler clecoed to spar

Shims and doubler clecoed to spar

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