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Traci and Tom's RV-7A
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Date:  5-23-2013
Number of Hours:  0.75
Manual Reference:  Sect. 6
Brief Description:  Cutting the bend strain relief in HS-702 spars.

After putting the 6 degree bend in the HS-714 and HS-710 spars, the matching part of the main HS-702 spars had to be angled also.
I admit that I mostly looked at the diagram of how to cut this and used a file to trim out the strain relief grooves and then realized that I did it wrong (in a way!). The manual said to used a #30 drill and then a larger drill bit to complete the hole.
I studied the diagrams carefully and used a file. As long as it matches up, who cares how it's made? I trimmed the flange back to the fold line at 5 3/16 inches (notice the sloppy line there, it's accurate, but I didn't have a straight edge small enough to fit in there so I connected the dots!) The other line is the tangent of the edge of the hole where it was filed to. Edges were rounded and smoothed out using ScotchBright pad and 400 grit paper (I'll keep saying that for a while until it's just understood I guess - seems a common task!).
I later cut the blue plastic off around the holes.
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Trimmed and ready for the strain releif grooves.

Trimmed and ready for the strain releif grooves.

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After filing the grooves, it's ready to bend.

After filing the grooves, it's ready to bend.

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View from the back side.

View from the back side.

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