Started working on the Vertical Stablilizer (VS) today. The kit states to start with the horizontal stablilizer, but the kit was missing the front spars. Van is shipping them but they won't be here until next week. I started with the VS back spar by clecoing the back support to the spar followed by the three rudder hinge supports They are suppose to be drilled with a number #30 drill (1/8th rivets), but the powder coat on the hinges would not allow a 1/8th cleco to go through. I used the 3/32 clecos initially until everything was together. Then I changed the 3/32 clecos to 1/8 on every hole that was large enough to allow them through without forcing the cleco. Most of the holes took the 1/8 cleco. It took a little extra time that way, but I wanted to make sure it was done right. As the plans require I clecoed the four ribs to the back spar and then to the front spar. After clecoing the spars I "drilled to match" every hole to size 30. That is where I made my first mistake. Its a little hard to see in the photo, but the top hole is oversized. I did not realize at the time that I had grabbed part HS-706 instead of VS-706. They are almost identical. But HS-706 is for the Horz-stab, not the vertical stab. At this stage I have two choices. I can use a bolt or larger rivet. The other alternative is to replace the rib and the front spar. I checked the price of both online and the total cost is $23.00 plus shipping. I am going out of town for two weeks anyway, so I am going to replace the parts. If this is my most expensive mistake I will really be fortunate.
