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Date:  8-1-2009
Number of Hours:  2.00
Manual Reference:  
Brief Description:  Wing Spar Holes 1

After first measuring the height of the spar drill holes using a plywood board under the spars, I found only .05 inch variance on the front holes. Accordingly, I made a drill guide jig from a bucking bar by drilling a 23/64 hole in the bucking bar after first squaring my mini-mill, and then used the drill guide to help control the drilling of the front spars, as suggested in the Avipro manual. I'd suggest drilling free hand until the hole is well-centered and started with some of the final width being cut in the aluminum, as the drill will have a tendency to wander, and you can't see what's going on when the drill guide is in place. I lightly chamfered the holes and polished them with 400 sandpaper and primed them afterwards.
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Drilling bucking bar guide.

Drilling bucking bar guide.

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Reaming to size

Reaming to size

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Primed.

Primed.

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