03 MAR 14: Page 8-9 step 6: 2.75 hours

Finished deburring HS skins and spent the rest of the session practicing riveting – no pics.

04-05 MAR 14: Page 8-9 step 8: 5 hours

Machine countersunk all the holes in the flanges of the front are rear spars and 3/32” holes of the stringers.  As other builders have cautioned, it is easy to get too deep on the end holes – be careful.  And, wow, are there a lot of holes to countersink!

Van’s recommends 7 clicks – which I believe is .007” – past flush. 

06 MAR 14: Page 8-9 step 8, page 9-2 steps 1-7: 6.25 hours

Spent the beginning of this work session finishing the countersinking of the HS spars and stringers.  With all HS complete and ready for priming, I moved on to the elevators.  Began with the 16 E-1008 elevator ribs:

On the advice of a fellow, local RV-10 builder, I will include more pics of me doing the work.  Take all of the ribs and cut them in half:

Deburring each half of the ribs – now 32 pieces:

Once cut and deburred, mark as E-1008 A/B, cleco together and final dril #30 the two common holes on each end of the rib half.  Label each half, so they remain paired throughout construction.  I then ensured the flanges of the E-903/904 outboard/inboard tip ribs were bent 90’ and straightened the ribs by fluting.  Checked for straightness using the holes in the E-913 skins.  Clecoed assemblies and final drilled 1/8” holes in the rib web, the 3/32” holes in the flanges and skin, and the 3/16” holes in the front of each rib.  Finally, separated the four E-1022 shear clips, final drilled #30 the holes in the short flange, and deburred the edges and holes.  This was a good work session as I feel like I accomplished a lot and finished a whole page of the plans – unlike the past several days of just deburring and countersinking a few parts.  At the end of the session, I was left with:

07 MAR 14: Page 9-3 steps 1-3, page 9-4 steps 1-3, page 9-5 steps 1-2: 2.75 hours

Bent close out tabs on E-1001A/B elevator skins:

Clecoed the E-1002 front spars to the E-1001B bottom skins:

Clecoed the E-1008 ribs and the E-905 root rib to the E-1002 front spar and to the E-1001 B bottom skin.  Clecoed the E-1007 rear spar to the E-1008 and E-905 ribs and E-1001B bottom skin:

08 MAR 14: Page 9-5 steps 3-4, page 9-6 steps 1-8, page 9-7 steps 1-4, 7, 8: 11.5 hours

Final drilled holes common to the E-1008/E-905 ribs, E-1002/1007 spars, and root rib:

Clecoed the E-615 trim access reinforcement plate to the E-1001B bottom skin.  Final drill the holes common to the reinforcement plates and skins using a #40:

Clecoed the E-921 elevator gusset to the E-905 root rib and the E-1007 rear spar.  Final drilled #30 the gusset to the rib and spar:

Final drilled all holes common to the tip rib assembly:

Marked edges of VA-140 trailing edge wedge between E-1001A top skin and E-1001B bottom skin:

Removed the trailing edge wedge and trimmed at marks on the band saw:

Match-drilled the #30 holes in the close out tab of the E-1001A/B skins and the E-1022 shear clip.  The angle drill helped with the hole closest to the rear spar:

I think the tabs ended up looking pretty good:

Clecoed the WD-605-L-1 elevator horn to the root rib and front spar.  Final drilled the holes common to the horn, spar, and rib with a #30 drill:

Final drill the skins with a #40 drill:

Positioned the WD-415 trim cable brackets on the E-616 cover plates and drilled #30 holes:

It’s all part of the process, but still a bit demoralizing to take everything apart again:

Spent the rest of the session deburring everything.  Also countersunk the spars and trailing edge wedges.  Weather is supposed to be very nice again tomorrow.  Hopefully I will be able to finish up and begin priming everything – VS, rudder, HS, and elevator parts.  I still haven’t put anything together – just prepping all the parts.