29 JAN 14: Page 6-2, steps 1-3: 3 hours

Cut rear spar caps, clamp along spar flange/web, match drill spar web:

Match drill spar flanges:

Remove all, debur, and reassemble:

30 JAN 14: Page 6-2 steps 4-5: 2 hours

Deburr rear spar doubler – took forever!!  Match drill doubler, spar, caps, hinges:

31 JAN 14: Page 6-2 step 6: 1 hour

Machine countersink spar doubler – VS-1008.  First time countersinking – took quite a while practicing and setting correct depth.  I think they came out pretty well:

The rivet is perfectly flush.  Only thing I’m not sure of at this point is if I should allow for priming.  I’m not sure if once I prime, the rivets may be just a hair proud..?  I’m leaving them as they are at this point, as I plan to shoot a very light coat of Akzo primer:

2 FEB 14: Page 6-3 steps 1-3: 4 hours

Deburred VS skeleton parts and cleco together:

Then cleco the skin to the skeleton.  I slightly fluted the rib tips to prevent the tips creasing the LE skin, but still got a couple tiny creases!  I removed the LE ribs and ground off about 1/8” from the tip – should have done that from the beginning!  I was struggling at one point to line up the holes of the skin to the ribs.  I remembered advice from VAF I received recently – if you’re ever struggling, feeling yourself going down the path of getting PO’d, stop and regroup!  Fortunately, I followed that sound advice and took a step back.  It was then that I realized I had the top rib – VS-1006 upside down!  After that, the skin clecoed together quite nicely!  Added a bit of time to tonight’s session (that and removing/grinding the LE ribs), but all and all, it worked out ok:

3 FEB 14: Page 6-3 steps 4-8: 5.5 hours

Final drilled VS, disassembled VS, and deburred all  parts.  Dimpled the VS skin – even though I forgot I wanted to dimple after priming.  Oh well, I’ll remember next time!

Had to wait for my wife to get home to finish a few of the hard-to-reach holes.  Her first time helping with the build!

VS skin all dimpled:

Last step for the night was to countersink the spar flange holes.  I’m using Cleaveland’s single flute countersinks and really like them.  I think I get pretty good results for a newbie!