*****This is the summary of the past few weeks. It does not include any of the time expended for planning, whinning, thoughts of doom, etc., etc., etc.
It has been more than a month since I have done any real work (on the plane). Summer gets in the way and I must admit to a bit of depression regarding the way things went. I still can't believe I managed to make such a mess.
I have remade the wing attach angles and wing attach blocks. Cleaned up the spar. Precisely drilled the new parts to match the old. Installed new parts.
The problem is that I no longer have small pilot holes to updrill - I have one block at 3/8 and the other completly undrilled. I really have significant fear regarding repeating my same mistake if I try to updrill this while wings are installed in the airplane. Others have done this drilling once the spars are built but before the wings are even built. I THINK THIS IS THE WAY TO GO.
So, I layed both wings out in my front yard and my wife and I mated them together. Lock in the indexing pins. Clamped it together. I passed the 3/8 bit through the previously drilled hole until it contacted the new block. I spun it enough to begin a hole then stopped. I removed the block and completed the hole in my drill press. Re-installed and shazam! Perfect. Went ahead and did the same thing with the undrilled set- they had the 1/4 inch pilot already. This was so simple.
Then with the assistance of my wife and a very mechanically inclined friend installed the wings into the aircraft again. Completed the rest of the wing drilling with some difficulty; mostly because I was so gun shy.
