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Cleve's Web Site
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Date: 10-31-2006
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Number of Hours: 3.50
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Manual Reference:
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Brief Description: Both rear spars step drilled without drift to 1/4"
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We have not had any entries in the Kitlog for the last few days because when we aligned every thing, checked sweep, triangulation and incidence, we had NO excess in edge distance on the right rear spar and we were terribly afraid that we might let our drill slip just a tiny bit and thus having inadequate edge distance. We have therefore been studying all the ways to drill the spar. I called Van's and told them about our close tolerance and asked if they had any suggestions. They gave me some classic information. They said, "Don't make any mistakes. Do it perfectly!" So today, that is what we set out to do! We had gone to a machine shop and had a drill guide made according to Van's specifications (2x2x1 in.) and drilled with a 1/8" hole. However when we tried it, it was too big to fit in the limited wing root space. I cut the block down to 1.25 x1.25 and had room. We then were left with how we were going to hold the drill guide in place while we drilled. We tried "C" clamps and vise grip pliers but didn't have enough room. We bought Vise Grip clamps but they were not steady. Then Claude thought of Channel locks and they worked perfectly to hold the block rock steady. Having worked through all these problems and having checked our measurements at least 10 times, this morning we drilled the spar with an 1/8 in. drill PERFECTLY centered. Then we drilled the drill block out to the next step and drilled the spar, again perfectly centered and with edge distance. We drilled to 1/4" without slipping and in Image #2 you can see for your self we were right on. Because I am left-handed & Claude is right-handed, we swapped jobs on each spar, one holding block with Channel locks and the other drilling. Tomorrow we will drill our last step and then finish with a 5/16ths. reamer for a final size. That is if the reamer comes from Avery today.
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Rear spar drilled and locked in place with a bit
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Rigth rear spar with hole dead in the bulls eye!
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