I removed the plywood top from the table in preparations for final assembly and drilling of the main spars. This allows for easier access to both sides of the spar. I assembled both left and right main spars for the first time since match drilling parts separately. I clecoed the #40 holes from the top and bottom sides. Everything fit and lined up well with the exception of I did have to grind a little off some of the lower (front side) vertical stiffeners to fit between the capstrips.
I'm pretty happy with the results of doing my main spars this way. In hind sight the only thing I think I would do differently is leave a #40 hole on each side of the capstrip rivet location that corresponds with the vertical stiffeners. I only left one side a #40 hole so I had to alternate clecos top and bottom (front and back) down the length of the capstrip where there are 4 layers. I would prefer to have one at each vertical stiffener location on both the top and bottom side.
I clamped the left main spar securely for drilling the final rivet hole size. I realized while I was working on this that I forgot to cut the 6 inch vertical spacers needed for 7 positions to match a single layer spar cap to a double layer on the front side. I cut these pieces and match drilled and clecoed them into position.
Today is 16 days straight working on the Bearhawk and I have to admit I'm getting a little burned out. I found myself sitting down and staring around the room more than usual. My time off is over and I'm back to work tomorrow, so I'll take a brake from construction for a few days now. So far I'm where I want to be on my hours and progress goal.
Setting Up for Assembly
Left Side Clecoed and Clamped, Right Side Clecoed
6" Vertical Spacers (Rear Spar Hanging on Wall in Background)
