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Date:  3-13-2007
Number of Hours:  3.20
Manual Reference:  
Brief Description:  Deburred and countersunk the longerons

Tonight I tackled preparation of the longerons for eventual riveting. First, I marked the end of the longerons at the tail and cut them off flush with the aft most bulkhead, using a whiz wheel. Then, I deburred the longerons and smoothed the cut ends with a scotchbrite wheel. Next, I had to countersink the outer surface of the holes to make room for the dimpled skins and the flush rivets. I started with the smaller aft longerons. Rather than chuck my countersink into the drill and hand hold the drill for the countersinking operations, I decided that I could just as easy fit the countersink into the drill press and then run the longerons through the drill press. I had no more than countersunk three holes when the countersink cage blew apart. All the kings horses and all of the kings men could not get it back together again. It seems as though an internal flange which held everything together simply wore out. Rather than just give up, I chucked the countersink cage shaft in the drill press and then set the drill depth stop so that it would cut the proper depth countersink. That worked pretty well. Later, when I got to the long top longerons, Vicki came to help me hold them while I countersunk them in the drill press. I will have to check through everything again, but I think I am through dimpling and countersinking the skeleton. Now, I have to prime everything and then cleco everything back together for riveting.
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The discombobulated countersink cage

The discombobulated countersink cage

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Longeron with countersunk holes

Longeron with countersunk holes

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Nekkid fuselage skeleton without the longerons

Nekkid fuselage skeleton without the longerons

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