Today I fabricated the horizontal stab front spar. I attached the two reinforcement bars to the two spar channels and drilled all center holes to #30. I then drilled two relief holes in the two spar channels. The construction manual does not call for this step. However, talking to other builders and consulting the blue prints, the decision was made to include them. I used a 1/4 bit.
The ends of the reinforcement bars were rounded per the blue prints and the edges polished smooth. The instructions call for making a simple cardboard template for measuring the bend angle of these ends. No cardboard; I used wood. It worked out well. Both bars and both channels were bent to 6 deg per the blueprints.
The four center rivet holes in the spar were dimpled to accept an AN426AD4 rivet with the factory head on the aft side of the spar.
Front spar bars and my first special tool...until I need a drill board.
Relief holes in the front spar channels.
Completed Front Spar. Still need to primer the bars though.
