September 26, 2007 ...  I spent several hours today updrilling the left upper and lower spar caps (with a #30 bit) and deburring. I then bored all of the 19/64 and 27/64 countersinks in the spar caps and spar web doubler plate. To bore the countersinks on the spar web doubler, I used a 100 degree X #30 countersink bit in a Mico-Stop, adjusted as needed to obtain the countersink diameter. On the spar caps, I used the same countersink bit attached to a threaded Hex Adapter that I purchased from Avery Tools   (Part # 1095),  You have to bore a little at a time and measure often when using the Hex Adapter.  On one section the Micro-Stop tool does not fit due to the angle in the spar caps. Also notice, I put some masking tape along the spar cap edge to protect the edge from accidental bumps during the countersink boring process.

October 1, 2007 ...  The few hours of "wing time" that I got today were very productive. I finished boring the last few countersinks, then updrilled all of the rivet holes (with a #21 bit), then updrilled the screw and bolt holes with a #13 bit. It won't be long before I will be riveting.

October 2, 2007 ...  I disassembled the spar pieces and deburred all of the holes one last time. I then went over each hole for a final check with the drawings. The rest of my time was spent cleaning up all of the spar webs with a liquid soap solution; rinsing and cleaning with Alumiprep; and after a final rinse and dry, treated all of the parts with Alodine 1201. I took a little time this evening to Cleco all of the spar web, spar caps, and a few of the brackets together. It is so great to see this spar come together so quickly, and so far everything fits great!

October 3, 2007 ...  Prior to setting rivets, I assembled all of the brackets and installed all of the "tight fit" bolts and screws called for on the drawings. If you are building, be sure to have a copy of the  factory revisions (printed off from the Sonex factory website) close by. The SNX-W08 drawing page calls for the wing mount bracket bolts to be inserted from opposite sides. The "Optional" revisions allow both  bolts to be inserted from the aft side of the spar See photos below.