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Sonex 815 Build Logs
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Date: 9-23-2006
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Number of Hours: 3.50
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Manual Reference: W21, W14
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Brief Description: Ail crank + wing ribs
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Spent about 20 minutes to reposition the spar from the table to saw horses to drill the remaining forward rib holes. Spent about 1 hour marking and cutting another W21-06 and -07 since the first pair was made from angle stock that was not quite 90 deg. I had spent some time earlier locating a scrap of 2x2x.125 and 1.5x1.5x.125. The 1.5 stock was tighter than 90, so I opened it up a little on the vise with the prybar. Cut out the new parts and drilled for the bushings using the unibit. Spent the other 2.5 hours or so positioning and drilling all the aft ribs to the LH spar including all the spacers. Drilled the .125 spacers first by taping them in position, spring clamping over the tape, then just "starting" holes in the center two positions. Took all this off, finished the holes on the drill press, clecoed the spacers back, "started" the remaining two holes per spacer, took this off, finished the holes on the drill press. Then did the two end holes on each of the .032 spacers using a pattern spacer that happened to have the right spacing on the end holes (the intermediate holes did not match the .125 spacers). Clecoed these .032 spacers over the .125 spacers and "started" holes in these. Took the .032's off, finished the holes on the drill press, taped the .125 spacers into position (left the .032's off) then positioned the ribs on the spar and drilled. Put the .032's back in, positioned the aft spar on the back of the ribs and drilled it too. Figured I might as well get all the ribs to final hole size and deburred prior to riveting the spar itself, then after the spar is riveted it's just a matter of clecoing it all together and riveting the ribs on.
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Rib spacing looks funny - the inner 3 ribs are at 1/2 the spacing of the others for the wing step.
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Starting to line things up for the aft spar.
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