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Peters Web Site
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Date: 11-19-2016
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Number of Hours: 3.00
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Manual Reference: 9225501-LOG-03.003
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Brief Description: Front Spars
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After what's seemed like an eternity getting the necessary tooling together, and my workshop in order, the day has finally come where I actually started to build something.
As per Vans instructions, I started by clecoing the front spar doubler HS-907 to the front spars HS-902, and then match drilled all the pre-punched 1/8" holes to #30. Very slow going as I checked and double-checked everything, especially before drilling any holes. I guess this will all become quite matter-of-fact down the track.
Next I started making the HS-908-L/R front spar attach angles. I found that the supplied aluminium angle is not 90 degrees, but is over-formed quite noticeably. I had a look ahead in the preview plans, but it's not evident if this is going to be a problem of not, so I've sent a message off to Vans Support to get their advice. In the meantime, I continued making the two parts with the material I've been sent.
The bandsaw made very easy work of cutting out the two shapes, then it was over to the belt sander to clean up to my layout lines. After this I then smoothed both parts on the scotchbrite wheel.
Holes are centre-punched ready to be drilled tomorrow (would you believe - I don't have a 1/8" drill bit!).
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UPDATE: Vans Support said that it is quite common for stock heavy gauge angle to be like this. They also said that it is important that the HS-908-L/R angles be adjusted to 90 degrees for correct assembly to the fuselage later, and that the method for getting it this way is to simply belt it with a hammer on the back of the angle (to spread the two flanges). I placed the angle on the smooth, cast iron bed of my table saw, placed a block of wood on top, and hit very hard with my steel mallet. This did the trick!
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Spar Doubler cleco'd to Front Spars
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HS-908-L/R Attach Angles marked out
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The bandsaw made quick work of cutting the angles out
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