07-20-2011: 3.5 hrs
Got some time to inspect the work and the spar, I noticed a punch mark around the most inboard nutplate hole on the top flange of the right wing spar. It might be caused by the slipped squeezer when I set the rivet yesterday, but I didn't notice yesterday. I don't think it's a problem because the hole is a bigger discontinuity than the punch mark. Anyway, i will send the picture to Van's and see what they say. Also, I noticed some scratch on the flange as well. These scratches should be there when the parts were shipped. I was careful about moving the spar so not to cause any scratch on it. Again, this should be ok, because the depth of the scratch is comparable to the labels written by Van's using the vibration (or electron) pen.
Update on 8/2/2011: Received email from Gus of Van's aircraft, the punch mark and the scratch are not a concern. Build on.
After the inspection, I went ahead and finished mounting the nutplates for the inspection panel on the bottom flange. Then I countersunk all screw holes (#8 for tank attachment and #6 for inspection panel attachment). I drilled the inspection attachment holes using 9/64 inch drill bit, instead of the #28 drill bit called out by the drawing. They are close enough. Also, I drilled and dimpled the inspection panel W822PP and use that as a reference for countersinking the #6 screw holes. According to other builder's sites, the common agreement on the coutersink diameters for #6 and #8 screw holes is
#6 screw hole: less than 0.3125" (5/16")
#8 screw hole: less than 0.375" (6/16")
All countersunk holes are within this spec.
The punch mark around the tank screw holes on top flange before the hole is countersunk
Another view of the punch mark
Scratch on the bottom flange of right wing spar
Punch mark after the hole is countersunk
Countersunk hole for the inspection panel attaching screw, diameter is less than 5/16"
Countersunk hole for fuel tank attaching screw, dia. less than6/16"
Threads on the #8 screw is smoothed off, the screw is used to guide the countersinking
The #8 screw is fitted in to the countersunk hole nicely
Right wing spar nutplates mounting is done, all screw holes are countersunk and primed
Close up view of the countersunk hole fr #6 screw
Typical nutplate installation
Left spar is out of the box
All nutplate riveting holes on the left spar are contersunk, nutplates are clecoed to the top flange
