Drilling the Rear Spar February 20th, 2006
Once the reinforcement bars have been rounded off and are nice and shiny, it’s time to match-drill them to the rear spar.
I laid the pieces on the table and drilled the outer two holes through the pieces and into the table. This allowed me to cleco everything down before drilling all the other holes. I also put in the brackets that go in the spar, so everything is match drilled in place.
This picture shows how I keep track of what part goes where after I take things apart for cleaning or deburring. I just draw lines at different angles through the different parts. When the parts are put back together correctly, the lines match. Now I gotta figure out how I’m going to keep those lines when I clean things up for priming!
It may be worth mentioning that when I first placed the reinforcement bars inside the rear spar, it was hard to get the holes to match without having a small gap between the bar and the spar. I went back to the grinder and radiused the bottom edge of the bar just a little bit more, and everything fit perfectly.
Since I had the hinge bracket in place, I match-drilled it as well.
