Good and bad day. I finished attaching the front/main ribs to my right wing main spar. I asked my wife to help flip it and I wasn’t thinking. I had her at the light/outboard end and I was at the other end. In addition, I decided to flip it with the nose ribs down so it wouldn’t be so difficult for her. In the process, the outer main wing spar extension folded on itself – see pictures 2 and 3. The way we did this put all the weight of the main spar pulling down on the spar and the flanges 8" outside of where the extension was attached began to fold.
I immediately sent Darryl Murphy (designer/manufacturer) a note and received a reply within several hours. His response was "Not too major. I have attached a sketch of how to fix it. Use 0.032” 6061-T5 or 2024-T3 bent up angle. Ensure the outside radius of the splice is not smaller than the inside radius of the W-509." Thank goodness this was in the outboard section where the spar extension doesn't really carry much load. I'll work on the fix tomorrow. And, thanks to Darryl for such a quick reply.
The rest of the day, I spent clamping two blocks of wood on the extension flange to pull the crimp out. I then proceeded with installation of the rear/main wing spars on the right wing. Good progress overall.
Lesson learned, be very careful with flimsy structures prior to attaching stringers/skins.
