Entry: Wed May 13 2020

This post covers short stents in the shop over the past 3 days. I've been trying to get out for at least an hour each day. Activities have focused on two tasks, prepping the jigs for the flanging, and deburring all the parts blanks.

The process for chamfering the lightning holes has been relatively simple process of setting the height on the router with a 45 deg bit and routing. The idea is to create to mirrored copies so that the flanges can be formed on either the left or the right side of the blank. So of course while processing my aileron jigs I made them duplicates instead of mirrors.... oops, so I'll run off another copy from my master rig shortly. The other issue this revealed is that the gap between the flanged lightening holes on my nose ribs is going to wind up at ~0.6" inches and on my 0.032 center ribs the spacing between the aft most lightning holes is going to come in at exactly 0.5". This is a challenge because 0.5" stiffeners need to be installed in these locations and it's going to be tight. Investigating my jigs I discovered that my lightning holes are an 1/8" oversized which was likely a transfer error of 1/16" while setting up the fly cutter....

On the deburring front I've gotten the aileron and back ribs finished. I have two drill presses in the shop so I've chucked up a 3" scotch-brite wheel in one that I use to deburr all the outside edges and radius corners. In the second drill press I've got a 1" scotch-brite wheel that I use to deburr the inside of the lightning holes. To finish I use an edge deburring tool on the lightning holes to remove any burr created by the scotch brite wheel. It's taking me about 5 min per rib so I process 12-15 ribs per hour. My stretch goal is to finish deburring by Friday.