The hardest thing about the HS front spar is definitely aligning, drilling and riveting the attach brackets. All that material, and the fact that everything must be kept perfectly square in the process means that careful planning is in order. I found that the best thing I had to make sure the brackets were square to each other and held solidly in place was the back riveting plate. By clamping the brackets to that and keeping the spacing regular between the spar and the plate, I was able to keep everything in place while drilling. Once all the holes were match-drilled, disassembled and deburred, I finished up by riveting everything in place. I highly recommend using the rivet gun and bucking bar for the rivets that pass through the attach brackets. The pneumatic squeezer might have worked, but it's a tight space. I'd hate to come down with all that force on the barcket by accident. Ouch.. That's why I bucked those rivets.
PPE is never cool, but neither is going deaf or blind..
The front spar doubler, caps and spar make for a lot of materials and a lot of clecos.
