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Patrick Kelley (Flion)
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Date:  11-17-2009
Number of Hours:  7.00
Manual Reference:  10-11.3 to 10-12.9
Brief Description:  Match Drilling; adding top skins

Miscellaneous stuff: Started to dimple elevator parts and discovered that the vice-grip dimpler from Avery was a #30, not the #40 I needed. No damage done but elevators back on hold until the right tool arrives. I did some investigating on converting the battery box to fit a 24V Concorde battery. I will not be able to make my own channel nor is it available from ACS. I can possibly make the bottom plate from .063. I will contact Van's tomorrow and see if they can make me up a blank channel piece, in which case I will order 3' from them as well as a 1'x3' piece of .063 for the bottom plate (the scrap will go toward making the servo mount for the AP pitch servo). If I can fabricate a bottom plate similar to the Van's supplied one, then I will; otherwise I will go for a flat plate edged all around with channel for the battery mount.

That out ot the way, I finished match drilling the bottom skins to the bulkheads and each other. Then I installed the F1009 bulkhead and pre-drilled the ends of the last three stringers (I should have done this on the first ones; it makes positioning them much easier). I added the aft top skin and clecoed it to the side skins and bulkheads. Then I drilled the stringers and finally match drilled the side skins and aft two bulkheads. Next, I added the forward top skin and match drilled all the stringers, side skins, and the rear bulkhead.

I followed the instructions and heavily fluted the two-hole tabs, despite misgivings. It seemed to work out well, though you can see from the second picture that the clecos in the bulkheads tended to be non-perpendicular to the skin. After match drilling, the clecos oriented normally (as the third picture shows) and the skins were drum tight.
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