Brief Description: HS Forward Spar Repair and Started Countersinking
Today I finished the repair to the forward spar because of the countersinking screw-ups. I cut a piece of .025" aluminum 3 1/2" by 7/16" and deburred it. Next I clamped it the the spar flange and marked the holes. I started drilling the holes using a 1/16" bit and moved up to a 3/16". I then stripped off the primer that I had on the spar with acetone and a scotch pad. After that I scuffed both the tab and flange with sandpaper. I then mixed and spread the JB Weld on the tab and cleco it on to the spar flange. I then clamped the tab on and remove the clecos so they wouldn't be glued to the spar. Then I waited overnight. The first photo shows what it looked like this morning and the last two shows what it looks like after re-priming. Finally, I drilled the holes out to a #41 drill. My plan is to us a longer rivet in these hole to account for the added material. I think a 3-4.5 will work. Later today I set up my new drill press. I should have bought one of these right off the bat. It took some suggestions from my wife (she is really good at figuring these things out) before I had it set-up to countersink the rear spar, but once it is set I can make really nice countersinks. I got about a quarter of the way through before I called it a night
