Time to start assembling the spar. First step was to drill the angles to the spar halves. This was pretty time-consuming, since I wanted to get the spar exactly straight (duh). After I had it jigged down to the bench I had to get the angles exactly centered and spread out exactly.
Exact, exact, exact. Everything has to be so exact. Man, it's just an airplane... 8^)
Ok, ready to commit drill to metal...here we go...
And here's the front spar, with all the center holes drilled and everything clecoed together.
The front spar has a 6-degree sweep outside the center section. The tapered ends of the angles needed to be bent as such. The plans called for making a simple cardboard template, which I did. The angle ends were clamped between two pieces of wood and bent.
Using Avery's vise-grip hand seamer, I bent the "tongues" of the spars (note that at this point I had already trimmed off the flanges on this part of the spars) to the same 6-degree angle.
Here's the clecoed spar, ready for the outer holes to be drilled.
After drilling and clecoing the entire assembly together, it's pretty much ready to be primed and riveted.
I additionally drilled the 5/8" hole in the left spar for the elevator trim cable to pass through...considering I'm putting in electric elevator trim, the power cable will pass through here instead of the actuator cable.
Here's the spar, clecoed back together and ready for riveting, after having been primed.
