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Thread: Drilling your Spars - CAUTION

  1. #1
    Senior Member Paul's Avatar
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    Default Drilling your Spars - CAUTION

    I thought it might be worthwhile to raise this RED FLAG of CAUTION for all first time builders.

    Drilling your spars

    When you come to the part of your wing build where you're attaching anything to the spars, be extremely careful that you do not drill outside of the safe zone of the spar. Mitch has added a number of details and some red ink to help you through this process and believe me, it pays to be ultra careful here. There's at least 3 parts that require new holes in the spars....

    - Front spar Pulley bracket (page 90, 91 in the wing manual)
    - Rear spar reinforcement (page 92)
    - Leading edge skin top edge rivets (page 143)

    Be sure to use a drill stop for all these parts and be sure your drill stop is set exactly to the depth of the metal you're drilling AND allow for the range of the compressed drill stop spring.DO NOT DRILL THE SPAR BULB.


  2. #2
    Junior Member
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    Default Re: Drilling your Spars - CAUTION

    I agree with Paul... This was a nerve racking part of the build! What helped for me was to draw a sharpe line connecting the predrilled center rib holes on the ribs before I attached anything to the spar. With the line in place I could assure a straight line in the sweet spot! When it came time to drill something like the leading edge skins, I would with the help of the jigs put the skins in place drill and Cleco the front holes (into the nose ribs). I would put a thin piece of wood under the back tab of the skins, drill the holes in their proper location remove the wood and look for the line. If I saw the line, I knew any hole I drilled in the spar would be in the sweet spot. Clamp and drill with drill stop.

  3. #3
    Senior Member N867SP's Avatar
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    Default Re: Drilling your Spars - CAUTION



    The real issue is the hole spacing and the length of the pin of the 4-4.


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    Pete
    ✈️CCK-1865-0078 N9PW
    Severna Park, MD W18

  4. #4
    Senior Member N867SP's Avatar
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    Default Re: Drilling your Spars - CAUTION



    Spar drill w/stop installed. Located as short as possible to prevent contact.

    The factory does not fully insert the cherry max rivets when installing the front pulley bracket they insert the rivet without contacting the bulb, then start pulling while continuing to insert rivet. This will prevent the pin from contacting the bulb and scaring it.


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    Pete
    ✈️CCK-1865-0078 N9PW
    Severna Park, MD W18

  5. #5
    Senior Member N867SP's Avatar
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    Default Re: Drilling your Spars - CAUTION



    Rear spar cap installation


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    Pete
    ✈️CCK-1865-0078 N9PW
    Severna Park, MD W18

  6. #6
    Senior Member N867SP's Avatar
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    Default Re: Drilling your Spars - CAUTION




    Sent from my iPad using Tapatalk
    Pete
    ✈️CCK-1865-0078 N9PW
    Severna Park, MD W18

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