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Larry Winger's 601XL Project
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Date: 9-23-2006
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Number of Hours: 6.75
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Manual Reference:
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Brief Description: Metal cutting experiments and rear spar parts redo
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In lining up my center ribs with the front and rear spars, I discovered that my rear spar web was too narrow. Because it was a Z bend (and the web measurement is from the inside of one bend to the outside of the other), my bend line spreadsheet was useless. That is obviously because the spreadsheet is designed to measure the web from the outside of both flange radii. The practical issue here was that the stabilizer skin would have to pull down almost 2mm to mate with the spar, and that simply wasn't an option.
So.....I spent the day remaking my rear spar, shim and upper/lower doublers. My hope is that I'll be able to use the rear attachment and just drill through the existing holes, but I'll know more about that tomorrow when I start test fitting everything again.
Not only did I remake the spar, but I tried at least four different methods to speed up and improve the accuracy of my long straight cuts. Flush finish router, circular saw set to two different depths, and a new, more rigid straight edge for the Olfa knife. Finally settled on the latter, but it was a messy, noisy, not-so-fun day in the workshop.
The only good news is that the new spar was spot-on at 80mm. That part of the mission was successful. I then went on to the doublers, did fine on the lower doubler, but over-bent the upper one. So...tomorrow I'll be redoing that as well. Did I mention my deepest metal cut to date and a nasty aluminum splinter. I think it's time for bed!
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