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Building Juliette Whiskey
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Date:  10-2-2006
Number of Hours:  1.50
Manual Reference:  Section 7-3
Brief Description:  Match drill spars/ribs

I began tonight by making 2 adjustable blocks to support the centers of the wings. I got this Idea from another builder's web site. It is very simple: 2 - 4x4 blocks (10" long) are connected with a 5/8" threaded rod. The rod has a washer and nut on each end. The rod is also free moving in the hole of the 4x4. The way you set the height is by turning the nut until a string along the spar holes all match up. Then the spar is level (without sag). I then began to match drill the main spars and the ribs. All went well until I began to do the rear spar. I noticed that the center hole in the inboard rib was not lined up with the hole in the spar. The hole was off center. I carefully looked at the plans and at first thought I might have attached the stiffeners on the spar backwords.......I thought "oh shit....I'm going to have to drill out all these rivets....". Upon further inspection, I realized the mistake was stupid, but much more easily fixed......I clecoed the left spar on the right wing and the right spar on the left wing. A very dumb mistake, but thank god I caught it early, before I started drilling and riveting. I reversed the two spars and everything lined up perfectly. You have to make sure things are done correctly and double and triple check EVERYTHING!! A good lesson learned. I also got some stuff in the mail today. 4 more scotch-brite wheels (1" & 2") from Avery and 4 books by Tony Bingelis. I'm also thinking about ordering a heated pitot system. I can get the mount now to install while I build the wings....then get the actual pitot system later. More stuff to think about........More match hole drilling tomorrow.
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Homemade adjustable support blocks

Homemade adjustable support blocks

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Match drilling spars & ribs

Match drilling spars & ribs

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Sting line used to level spar...

Sting line used to level spar...

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