Test Front and Rear Spar assembly with ribs

Working through the day, I have prepped  each rib by fluting and deburring. Here is the test assembly. Starting to take the shape of something recognizable.

After test assembly, I have taken the pieces apart again for final finishing before they are ready to prime. As part of the finishing, I am required to shape each piece where the skin will encounter a gap. This is necessary to avoid a corner or edge in the support rib from pushing up on the skin causing and undesirable ridge. To speed things along, i have been using a scotch bright wheel (like a grinding wheel but much softer). Unfortunately I must have been a little over zealous and have have taken off to much material. I have sent an email to technical support to ask if it is necessary to replace the part or if I am fine. I placed it next to a good part for comparison. I am going to guess that it is fine. There is still plenty of material for the skin / leading edge to sit against to form the proper shape; however, Van's technical support will have the final say. Probably many more ruined parts to come.

Calling it quits for tonight before I ruin anything else.

today was my first crack at dimpling and counter sinking.

First I set up the tool.

then make the cut on the actual parts.

Calling it a night. Here is progress for this session. I have completed the drilling and assembly of the front spar for the horizontal stabilizer. Now it is just about ready to prime.

you might see that I didn't quite get the top reinforcement angle bracket right. It is just peaking above the spar itself. This will interfere with the skin when it goes on. I will need to file this down just a bit.

This piece requires an angle of 6 degrees. Using a cardboard template to get the angle right.

one part at a time folks. Used a hand file to shape these four ends. My band saw is still in New York. About 4 hours of filing.

I have also been building over the last few days as well.

Rear Spar complete - ready to be primed

Front spar now underway

I have not posted in a few days as I have been concentrating more on building than posting. My parts for the shop computer have arrived today so now it will be easier to post as I work.

For those of you that don't have a clue what I am building, I will post some pics and information about the finished product.

This will be a 2 seat Experimental Aircraft with about a 1,000 mile range. I am told that construction time will generally be around 2,000 hours. Many people complete the project in around 2 year. Many people also never finish.

This photo is of a factory plane I believe was constructed by VAN's Aircraft as a demo.

For more information here is a link to the kit manufacturer.

https://www.vansaircraft.com/public/rv7.htm