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Date:  7-1-2010
Number of Hours:  2.00
Manual Reference:  N/A
Brief Description:  Drill doubler and spar web, prepare for riveting

1. Transfer punch spar cap rivet holes in doubler.

2. Remove doubler, mark and center punch holes for doubler-spar web joint, 10-mm edge distance, ~30-mm pitch, starting about 10-mm from the spar caps.

3. Pilot drill, 3/32", the 16 holes through the doubler.

4. Insert the doubler back between the spar caps and the spar web. Enlarge the spar cap rivet holes, 1/8", 3/16", finally, #11, clecoing the the doubler in place. My new air drill is wonderful to work with. Much quicker than using the electric drill. Fig. 1 shows the drilling setup with the doubler clecoed in place.

5. Enlarge the doubler-spar web rivet holes, 1/8" & #20.

6. Remove the doubler:
- deburr
- scour with ScotchBrite
- clean with solvent (I've started using camp fuel rather than MEK, since it is probably less toxic, and no more flammable.)
- Prime w/ Cortec

7. Use compressed air and a paper towel to try to remove any chips between the spar caps and the spar web.

8. Deburr the spar web holes, and prime the spar web between the spar caps. I didn't prime under the spar caps, because I feared that the primer would wick into the tight joint between the spar web and the spar caps, which could create a blob of primer that would make it difficult to insert and align the doubler.

9. Left the parts to dry overnight.
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Drilling doubler & web

Drilling doubler & web

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