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Brent s RV-8 Project N784DE
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Date:  1-14-2007
Number of Hours:  2.00
Manual Reference:  
Brief Description:  Wing spar counter-sinking

Started actual contruction on the wing today. The plans call for counter-sinking the holes in the top and bottom of the spar where the fuel tank screws attach to the spar flange. There are plate-nut that get installed to capture the screws. After spending some time marking the spar (up, down, left, right, front, back) per the plans. I built a fixture to help stabilize the micro-stop counter-sink so it doesn't wobble and cause the hole to elongate. I got the idea off of another builders website and researching Vansairforce.net. I drilled it to match a nut plate and I clecoed it into place and then clamped and removed the clecos to allow room to counter-sink. I also stabilized the spar so I could work it on the bench. I also taped off areas to keep the metal chips from getting in the seams where the spar is built up. It took me longer to setup the micro stop then it did anything else. Per my research and Vans RVator newsletter the #8 screw counter-sinks should be .375 OD. Seems like a big hole, but it works well. The nut plate is where all the loads are carried anyway. I only got 13 done before I had to quite which is about half of the top flange on the left spar. I still have the bottom flange and the other spar to do. It should move fast now though - the setup takes all the time. Then I will go back and countersink the rivet holes for the nut-plates #40.
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stabilizing the left spar for counter-sinking

stabilizing the left spar for counter-sinking

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Fabricating a

Fabricating a "drill fixture" for the counter-sink pilot to ride in. Keeps the holes from elongating.

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Counter-sinking with the drill fixture clamped into place. Worked great!

Counter-sinking with the drill fixture clamped into place. Worked great!

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