Finished Tank and Access Platenuts - 10 hours

Huge day in the garage! I started to prime the HS#2 front spar parts as well as some wing platenuts.
Then I set to work on riveting on the platenuts. The majority of the platenuts go on very easy. however, the angled platenuts are a tad more challenging.  Installation of cleco's also presents a challenge with using my squeezer. I found if I used then from the inside out allowed much better access for the squeezer.

 
Setting the rivet closest to the spar web is a bit difficult as the factory installed rivets in that area limit clear access with the squeezer. I ended up having to drill about 5 or so rivets that stuck up just a bit too much. To my delight drilling out the rivets went extremely well and I re-set them.  
Before attaching the #6 platenuts for the access plates, I began to wonder if I needed to drill out the holes for the #6 screws (as they won't fit thru the holes as-is). So back to reading the instructions/forums/buildlogs. So I determined that I keep going and don't drill just yet. That lead me to wonder about countersinking the #6 holes. Everything I read is <0.3175", But nothing is definitive. So I grabbed the access plate drilled, deburred, dimpled it to #6 and then grabbed a piece of scrap and set out figuring out the proper countersink depth. After much back and forth I settled on a countersink diameter of 0.300" This allows the #6 screw just below the surface with a slight halo around it, which seems to be inline with the description on the forums. And it is also just clear of the edge of the flange. I also reasoned that at that depth it helps to ensure that I don't countersink too deep and ruin the spars and it provides a decent fit of the plate.

 
Of course though....I will get a second opinion on this before I go too much further.

Update, I ran this by my friend Mike who is an Aircraft mechanic by trade, and He was please with what he saw. It's nice to have knowledgeable people around to bounce things off of.  

Once I felt confident that I had the access plate platenuts figured out, I completed riveting them on the spar.Once the Left spar was done, I then continued on to the right spar. By midnight I was done!

 

Countersinking Wing Platenut Attachpoints & Priming - 3.5 hours

I completed countersinking the #40 holes for the platenut attach points. It was a slow process as I took my time to ensure the countersink cage is nice and flat on the piece. I would check, check and re-check as I went. Marking pieces OK when I was happy with the countersink depth.
I've began keeping the laptop nearby. Its quick reference to Vans Airforce / Buildlogs, and of course...Netflix!

I then took an hour to start priming platenuts. This is an idea that I had picked up from wirejock. I reason that it's an extra couple of steps to clean and prime them. But it seems worth it to me, as they are steel and priming will help mitigate rust.

Completed match drilling of the HS#2 - 3 hours

Now all that was needed was to match drill the HS skins. I had cleco'd every second hole, so I drilled each open hole. After I did a line of drilling, I checked then off with a sharpie as I went. From my previous empennage, I noticed that the odd time I would re-drill a hole that was already done and this increased the risk of making a hole oblong. So checking off a completed hole mitigated the risk.

At the end... Everything came out great.

Completed drilling the HS#2 front spar - 4 hours

Started off the evening by un-clecoing the skins on the left skin and marking out the holes for completing the cuts on the HS-702 spar. I then cleco'd the ribs and match drilled. I completed the cuts on the relief hole at the end of HS-702 and fitted everything back together on the skins. I prepped the new HS-00005 and set in on drilling the ribs to the front spar. Everything went extremely well, and I am very pleased with the workmanship. Finally!!!






































I un-cleco'd the skins and then began to drill all the remaining holes on the front spar outboard of the HS-00005/00006 ribs. I was sure to use my drill press and ensure that all holes were as straight as could be.

Resumed drilling the HS#2 - 1.5 hours

The news parts arrived from Van's and I wasted no time trying to get back to when I needed to be. I marked out the bend lines and trim lines on HS-710. This time around I was very careful to mark out the line that is 7/16" below the top edge. I then began to work on the new HS-702 spar. (Im still not a fan of bending out those tabs, never looks clean and nice as the rest of the pieces).

My friend mike came over to work on his HS for his Stewart S-51. We spent a couple of hours setting the hinge locations. Much more thought and planning involved with the S-51 than the Vans.

Countersink Wing Spars - 3 hours

I had ordered the new parts (hs-00001, hs-00005, hs-710, hs-702) for the VS#2, so until they arrive I decided to move onto the wing spars. I've been doing lot's of reading on other blogs to ensure I have my steps down right.

First I set up the table by applying tape, to protect the spars from scratches. After clamping both spars to the table, I taped the gap between the spar flange and reinforcement spar to ensure I kept metal filings out. Then I began to match drill the #40 holes that hold the platenut rivets.


After the match drilling operations was complete (I checked holes off as I went). I then began to countersink. I tested and re tested the countersink on scrap and have it dialed in perfectly.

 As extra precaution, I have decided to prime the countersunk holes (The instructions mention to do this on the screw countersinks, but I will also do the platenut rivets as well. I used a q-tip and dipped it in primer)

Nearly completed drilling the HS#2, Nearly... - 8 Hours

I tried to put in another stellar day in on the HS. Everything was going extremely well. I fitted the spars and ribs together. Worked on the HS-710/714 angles. Cleco'd on the skin. 

Began to fit the HS-00005/00006 ribs. Finished the left side and began the right. Then I noticed I made a terrible error. I drilled the hole fitting HS-00005 to HS-710 centered in the angle, not 7/16" down. The hole is too high up and edge distance is an issue. Silly mistake as I was going too fast. It only affects a few parts that I have to redo. Fortunately I didn't drill that hole on the right side, so i'm still ok. Normally I'd be quite ticked off.