09 MAR 14: Page 9-7 step 8: 5.5 hours

No pics today.  My grand plan of finishing up the deburring AND priming didn’t happen.  Heck, I didn’t even get the deburring done.  I spent the second half of today’s session second guessing some of my countersinking.  The countersinking on the .032 spar flanges – namely the VS and elevator rear spars – enlarged the 3/32 rivet hole.  I’ve read this dilemma on many web posts – backing the material, using a drill press etc.  The good news is that everywhere that you CS the .032 flanges, it is sandwiched between two pieces.  In the case of the VS, the skin and spar caps; in the case of the elevators, the skin and the trim tab hinge.  Because of this, the consensus is it is ok according to Van’s tech support – if not ideal.  This really seems like a common conundrum – counter sinking thin pieces (less than .040) to accept dimples, how to measure what is deep enough, etc.  Section 5 of the plans calls for 7 clicks of the countersink cage past flush – or .007.  Ken at tech support said the dimple should be barely past flush – just a couple or 3 clicks.  Well…this is all part of the experience, right…?

10 MAR 14: Page 9-7 step 8: 2.5 hours

Duburred skin holes/edges – rivet practice.  No pics.

11 MAR 14: Page 9-7 step 8: 3.5 hours

Continued deburring elevator skin holes and edges.  Fairly slow going.  Almost have 2 down, 2 to go:

12 MAR 14: Page 9-7 step 8: 3.5 hours

Not much done tonight – more riveting practice and plugging away at deburring the skins.  Debur, debur, debur:

13 MAR 14: Page 9-7 step 8: 3.5 hours

More skin deburring.  Also started the trim tab foam ribs and wood clamping blocks.  No pics.

14-15 MAR 14: Prekoted VS, rudder, HS, and elevator parts: 5.75 hours

Doesn’t look like much, and doesn’t feel like you’re accomplishing much.  It’s a ton of work and not very rewarding, but it’s all part of the process!

16 MAR 14: Finished Prekoting VS, rudder, HS, and elevator parts and : 8 hours

Again, doesn’t look like much, but it’s A LOT of work:

Taped off the rib and trailing edge area of the elevators in prep for priming.  Just have to break the trailing edges of the rudder and elevators and then I’m finally ready to prime everything: