Today I started on the VS-1008 (4th attempt) rear spar doubler. I took a different approach with deburring and it was much more plesant.
I got some 60 grit emery cloth from AveryTools and used it to remove the edges. Then I fine tuned it with 120 grit emery cloth. Finally and smoothed it out with 280 grit emery cloth and polished it with a maroon scotchbite pad.
This was too easy. I will always debur heave aluminum this way now.
I clecoed the skeleton together and final drilled the holes of the skeleton before disassembling and deburring.
I also countersunk the holes below the upper attach holds on the rear spar doubler. I used the drill press for the coutersinks and they came out perfect. One tip: remove the two spar caps when doing this, you'll find that the rear spar will lay flater and you'll end up with much nicer holes.
