October 8, 2007 ...  Working from the inboard end to the outboard, I finished setting the countersunk rivets and started setting some of the protruding head rivets on the web layers. After all of the rivets are set in the web layers, I turned the spar assembly over and set a few protruding head rivets so the shop heads land on the spar caps (inserted from the aft side).

October 9, 2007 ...  I got plenty of  "wing"  time today, and I made great progress!
Both wing spars are now riveted ... YEEHAW!   I made a final inspection of all the rivets and found 13 bad ones which I have replaced.  Hmmm ... That's more than the right spar. Oh well, it's done right now, and that's all that really matters. I carefully scoured page SNX-W-08 of the drawings to make sure I have everything in place correctly. So far, so good!

October 12, 2007 ...  Now that  the wing spars are assembled, I feel like I am probably going to surge ahead. Small projects and assemblies like the spar tip seem like REALLY small projects by comparison. I only spent about 1.5 hours in my shop today, but in that time, I fabricated, pre-drilled, and Alodined the spar tip assembly.

October 13, 2007 ...  After about 5 months of work, I finally turned the page (SNX-W08)!   I moved a few pages back to the Aileron Bellcrank (SNX-W21) which will be assembled on wing rib #9. I have already fabricated the aileron bellcrank pivots, so all I needed to do was fabricate the support brackets. These are fast and easy, and I was able to make brackets for both wings from some leftover scrap material instead of cutting from new stock.

October 15, 2007 ...  I was going to align and updrill the main wing spars but didn't feel I had sufficient time today. Because of the critrical nature of that process, I want a wide margin of free time. So instead, I worked on Rib #9 (Left Wing). First, I added spacers and assembled the left aileron bellcrank. It is necessary to do this first, prior to pre-drilling, otherwise the pre-drilled holes on the bellcrank bracket won't line up if you assemble with spacers later. After laying out the location of the holes and predrilling, I realized that two of the holes were in the wrong spot. So that rib went to the scrap box, and I will have to order another one. (Actually, I could probably use the rib elsewhere but I am choosing not too.)

 

October 16, 2007 ...  I measured and predrilled a new rib piece; predrilled and updrilled both of the channel pieces, brackets, and the aileron bellcrank assembly. I cleaned up the rib, channels and brackets and Alodined everything. Then riveted the whole assembly together according to the drawings. I have included two photos, so you can see the aileron bellcrank assembly installed.