04 AUG 14: Page 13-4 steps 1-4: 1.5 hours

Ran #40 drill through all 3/32 diameter fuel tank attach nut plate and wing attach nut plate rivet holes in the web of the spar assemblies.  Ran #30 drill through the three spar doubler to spar web rivet holes in the web of the spar assemblies.  Machine countersunk those holes – no pics.

05 AUG 14: Page 13-4 steps 6-9: 2.5 hours

Fabricated the W-1020 tie-down brackets.  Taping the holes for the tie-down rings:

Match-drilled the holes in the tie-down brackets using the holes in the spar web assemblies.  Match-drilled the nut plate attach rivet holes in the tie-down brackets.  Deburring the holes in the tie-down bracket:

Countersunk the aft side of the tie-down brackets for the heads of the nut plate attach rivets.  Final product ready to be primed:

07/09 AUG 14: Page 14-2 step 1: 8 hours

Deburring and fluting all ribs.  Tedious and monotonous – a few of the ribs:

10 AUG 14: Page 14-2 steps 2-10, page 14-3 steps 1-2: 7 hours

Finished priming the main spar flanges.  Cut the W-1029C angles:

Cut the W-1029D&E spacers.  Clamped the W-1029A-L torque tube support bracket, W-1029D spacer, and W-1029E spacers together with the centerlines aligned with the holes in the support bracket.  Match-drilled the spacers #30 using the support brackets as a drill guide.  Clecoed the VA-146 flange bearing between the W-1029A-L/B-L.  Clecoed the assembly to the upper and lower flanges of the W-1010-R inboard wing rib.  Clamped the W-1029C angle flush against the aft face of the W-1029B-L support bracket and inboard face of the wing rib.  Match-drilled #30 and clecoed the W-1010-R inboard wing rib to the W-1029C angle using the holes in the rib as a drill guide.  Match-drilled #30 and clecoed the W-1029A-L/B-L support brackets to the W-1029C angle at two attach points using the support brackets as a drill guide:

Match-drilled the holes common between the support brackets and the flange bearing.  Disassembled all parts and clecoed the W-1029B-L support bracket to the angle and match-drilled #30 the remaining attach holes. Clecoed the flap hinge ribs and flap hinge brackets to the inboard wing ribs:

Match-drilled #30 all common attach holes in the assemblies:

Removed the flange and flange radius from the top and bottom tabs of a single W-1011-R inboard wing ribs.  This notch removes interference between the outboard-most tank attach nut plate and the rib – essentially you’re cutting one of the holes off of a two-hole tab.  This was going well until I cut the wrong side of the tab off!! Oooops!  This is the bottom of the rib – how it should look.  This is the tab I mistakenly cut off on the top of the rib:

Thought about ordering another rib, but then decided to fabricate another tab instead.  Cut, deburred, and bent the tab in a vice:

Clecoed the rib to the spar and outlined where the tab needed to be drilled:

Top/bottom edge distance lines and centerline drawn on the tab.  Minimum pitch for two 3/32 rivets indicated by micrometer – all distances look good:

Manufactured head side:

Shop head side:

Looks good: