Wow, was this complicated/scary or what? Not having any experience with metal-work or building an airplane, my nervousness was off the charts when I began to drill holes into the spars. I spent many hours reading the material and planning each hole that I drilled. Everything was difficult. This was my first drilling of a larger hole – very nerve-racking. However, all holes were drilled properly.
The picture on the left was an interesting delima. Based on my limited understanding of the world of metal and riveting, I’m reading the instructions and trying to follow them exactly. You can see in the middle location the large rivet is sticking out about 1/4 inch because of the insert inside the spar. However, with a little advice from Mark Pringle and a little pressure when I pull the trigger on the rivet gun, the rivet seated perfectly.
Both wing spars (Forward and Aft) were drilled according to Rans requirements. Three bushings were inserted correctly with very little (no movement – very difficult to insert bushing) space. All bolts were torqued to 38 inch-pounds.
A few more pictures of spars being assembled.
Installing these connectors required about 1 hour each. The bushings, which are part of the insert had to be filed by hand to make sure the insert ultimately fit perfectly (and very tight) into the spar. Definitely required some patience.