Empennage Kit

Finish Fitting Horizontal Stabilizer & Main Rib to Front Spar MIS-DRILL

 

11/15/03, 5.5 hrs

 

I finishing fitting horizontal stabilizer components and after clecoing all the skins on the horizontal stabilizer, all holes were match drilled.  The vinyl coating was stripped using a soldering iron so that the holes could be deburred and later dimpled.  Tami was a tremendous help deburring all the holes on both skins.

Below, I was trying to drill the main rib, nose rib, and front spar on the left hand side of the horizontal stabilizer.  Per the instructions, I measured 1/2 inch from the last hole (shown by the silver cleco), marked and drilled the hole.  The hole came out good with the exception that it appeared closer to the edge of the spar reinforcement than I would like.  A review of the drawing indicated that the 1/2" mark for the hole in the spar reinforcement should have been 1/2" from the edge of the nose rib FLANGE being held by the silver cleco.  I have just over 1 hole diameter from the edge of the spar reinforcement.  I would prefer to have 2 hole diameters.

 

 

11/16/03, 2.0 hrs

 

After disassembly of the horizontal stabilizer, I was able to better see the mis-drilling in the pictures for this log entry.

This turned out to be very disappointing.  As you can see on the main rib (HS-405, right side), one of the holes turned out to be double drilled.  The rib must have moved while I was match drilling.  I decided that this double hole would not adequately hold the rib to the spar after riveting.

The main rib (HS-405, left side) has the top hole very close to the edge of the flange.  I went back and measured the distance from the edge of the flange to the edge of the hole.  It was less than one hole diameter.  I decided that this tool was not a condition I wanted to leave in the final assembly.  Therefore, I ordered two new main ribs (HS-405), front spars (HS-702) and front spar reinforcement angle (HS-714) from Van's.  This replaces all the parts I felt needed replacement due to my drilling mistakes.

Additional Note:  You have to drill a relief notch in the front spars (HS-702).  If you don't read the print and Van's instructions carefully, you will end up with a notch(s) that look like these.  The front spars are made to fit both the RV-7 and the RV-8.  My first relief notch was at the end of the factory spar flange.  However, after reading the print closer, there is a little note called "STEP 1", which states to trim the spar flange back to the bend line...  HUH?!?!  Get out the ruler!!  Dang, is anything going to go right????  I just assumed that the bend line would be at the end of the flange.  I didn't even consider the fact that Van's is using this same part on multiple planes.  Won't make that mistake again, I hope.

 

         


Last Updated: February 21, 2004