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Date:  5-18-2010
Number of Hours:  2.50
Manual Reference:  
Brief Description:  Laid up and drilled stack of spar webs

Finally got started on assembling the first spar web assembly. I found that my W10-03, which I had cut months ago, was too wide top to bottom, so I remeasured and shaved it down with a belt sander and some files.

As in photo #1 I aligned W10-03 over the top of W10-01 (I took the photo after drilling and taking everything apart, so before I started there were NO holes in W10-03). I stuck them together with double-sided carpet tape (you can see some of the tape sticking out in photo #2).

Then I laid the other 2 web pieces (-02 and -05) on top. They aligned with W10-01, so I used a scrap aluminum angle laid on my workbench. and held the vertical face against the top edge of W10-01. Then I brougth the other 2 webs up agains the vertical leg to make sure they were aligned with -01. I then stuck those 2 pieces to each other with double sided tape, and finally stuck that assembly to the first assembly assembly (from photo #1) together with the tape.

I flipped the whole thing over (photo #3) so I could use the holes I had already drilled in W10-01 earlier this week, as a template to drill through the other web pieces.

I did NOT DRILL THE HOLES ALONG THE OUTERMOST TOP AND BOTTOM EDGES. I will wait to drill those AFTER I have set up the spar caps in the assembly. That way I will drill aligned holes in all 3 webs (W10-03 does not touch the spar caps, so it's only 3 layers + the spar caps, rather than the 4 layers, and W10-01 already has all its holes at this point).

It's a damn lot of holes to drill!!
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Start by aligning W10-01 and W10-03

Start by aligning W10-01 and W10-03

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See the

See the "pocket" formed to take the vertical flange of the spar cap

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All 4 webs stacked, stuck together with double-sided tape, and flipped over for drilling

All 4 webs stacked, stuck together with double-sided tape, and flipped over for drilling

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