Brief Description: Drilled most of HS front spar frame holes
Long day. When I first tried fitting the front spar assembly to the rear spars and ribs I assembled yesterday, it was was a total mess. None of the parts seemed to be fitting together as they should. All the angles and distances were off. After a couple of hours, I finally figured out that I had made a bad assumption about the angles around the two inside ribs (the ones with the lightening holes). When I broke out the calculator and computed the angles, I realized I was off by 2-4 degrees. It doesn't sound like much but when I pulled those ribs out and adjusted the flanges to the correct angles, the front spar position was much closer. I made lots of little adjustments here and there and finally got an acceptable fit. The only significant issue remaining was that the left tip rib didn't quite contact the front spar. This problem is mentioned in the plans as well as the fix: insert a shim to fill the gap.
Once the front spar position was set, it was relatively straight forward to mark and drill the rivet holes. It goes kind of slow since you've got to measure and mark everything and then check you work at least once on every rib. Still, if you're careful and don't make any major boo-boos, you can make steady progress. I had hoped to get everything drilled tonight but I got tired and hungry. There's only four more rib sections to match drill to the existing holes and a few remaining rivet holes in the front spar doubler.
Goal for tomorrow: Finish the drilling, modify the jig, and mount the fully assembled HS frame to it.
