After a few months of gathering parts and advice, the recovery from a construction error on the LH wing is complete. During the original fitting of the leading edge skin, a deviation from the Rans manual procedure was used in an attempt to simplify the handling of the leading edge, as well as to minimize dents and other handing damage. Rather than drilling one side, wrapping the the leading edge skin around the nose ribs, and drilling the other side, the sides were drilled separately. This deviation resulted a kink in the leading due to the misalignment of the holes between the top and bottom spar cap. The only good solution was to replace the spar.
1. Installed a new main spar with a new part from Rans. Reamed attach bolts and center spar to 1/64" ovesize and obtained NAS6606-30X and NAS6606-34X bolts.
2. Installed new bottom aft skin and tank skin. Since the ribs and aft spar were already drilled, the 3/32 holes were enlarged and the skins cleco'd to the frame.
3. Flipped assembly over and installed the orignal top skin. Transfer drilled the 3/32 holes from the original leading edge fitting to the main spar.
The assembly is now ready to flip over and continue installation of the leading edge.
