Finished drilling the HS

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Short, but productive day.

It was Jack’s birthday today (he turned 3), so I ran out to Chik-Fil-A to get him is once a year human food treat. A chicken biscuit. Of course, Ginger needed one too (“so she doesn’t feel left out”) and so on, which meant my girlfriend and I also got biscuits. Here are Jack and Ginger.

Jack and Ginger (Jack's on the right) on the beach last summer. Happy Birthday Jack. You're 3 now. Start acting like it.

Anyway, after the birthday festivities (a.k.a. Jack and Ginger inhaling their biscuits), I managed a couple hours on the project. Here, I clamped HS-404 in place after having first marked holes and drilled #40 pilot holes in the aft flange. The instructions have you mark and drill pilot holes in the HS-405, but why drill from aft to forward, hoping you don’t run into edge distance problems when you could drill from forward to aft? For the outboard holes, I did use the HS-405 for pilot holes. You’ll see.

HS-404, with two pilot holes marked and drilled prior to mock-up.

Here are the silver clecos after drilling from forward to aft with my 12″ bit.

Used the #40 pilot holes I previously drilled in HS-404 to drill through HS-702 and HS-405.

Then, I used the previously marked and pilot drilled holes in HS-405 to drill forward through the HS-702 (front spar) and HS-710/714 (reinforcement angles). The 12″ bit really came in handy here.

Then used the #40 pilot holes I made in HS-405 to drill through HS-702 and HS-710 (or HS 714 for the other side). Here, you can see the 12" bit really showing its stuff.

Then, I matchdrilled the rest of the HS-404, which had been clamped in place in the above pictures. After that, I finished match-drilling the rest of the skin for the right side. After you finish and pull the skin off, you can drill the remaining HS-702 holes using the HS-710 and HS-714 angles as guides. Here are the last six holes drilled after pulling off the skin.

Finished drilling HS-710 and HS-714 after removing the skin.

After the skins are pulled off, I’m ready to start prep for final assembly.

After match rilling both skins and finishing the HS-710/HS-714 to HS-702 holes, The skeletons lay ready to disassemble, deburr, dimple, edge finish, surface prep, and prime.

2.0 hours today. Not bad.
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