Van's aircraft are the most popular kit out there. With over 4000 flying, you can find how others builders did the same tasks on the internet instantly. That is one of the reasons I chose Van's. If you ever get stuck or need to see photos of how something goes together, just check out other builders. This can also not be a good thing, because some builders will overthink certain tasks and make it more difficult. Now, don't get me wrong....I am very gratefull to all the builders out there that take the time to do a web site, but sometimes the Van's instructions are the way to go. I'm talking about the countersinking of the spars for the tank skin connections. I've seen builders have a hell of a time with this task. I spent hours on it tonight trying to figure out a way to do it correctly. The way that ended up working the best was the way the Van's manual says to do it! I drilled the rivet holes to size, then countersunk. Then riveted the platenut on and used a drill driver w/ a countersink cage and a #30 countersink bit. The end of the bit centers perfectly in the platenut and makes a perfect countersink. There are 31 of these on each flange of the wing and there are two wings.....124 platenuts with 3 holes each.....372 countersinks!! I got about 1/4 of them done tonight. Tomorrow will go alot quicker...I also placed an order to Van's this morning. I ordered a quart of pro-seal (for building the fuel tanks), 2 tank fuel pick-ups (instead of having to fabricate my own), 50' of nylon 3/4" conduit (for the wing tip lights and landing lights) and 2 tie down eye bolts (these are removable during flight and install on the ground). I also got an order in the mail today for 10 - 60cc syringes that I will use to apply pro-seal during the fuel tank contruction. More tomorrow.....
Tank skin attach platenut riveted on behind spar. Hole is countersunk for flush connection
Hole on left is countersunk, hole on right is not. Tape is to keep filings from between spar parts
