After that it was on to final drilling the spar and stiffeners. Here you can see the process...clecos going in every few holes as they got drilled (note the particle board backing so I didn't drill through the bench...I still managed to drill into it a bit somehow).
Next the elevator hinge brackets had to be drilled in place on the spar. Here's the center hinge bracket assembly, with the bearing already installed and riveted in place. This had to be drilled, deburred, and riveted together.
Long story short, I spent a while deburring the spar edges and all the holes I drilled in the spar sides and stiffeners. There were like 47 or so holes on each stiffener, which meant something like 376 holes that needed to be deburred.
After all that was done, and the spar components were ready for assembly, I used Alumiprep 33 with a ScotchBrite pad to clean and etch the parts. I then brushed on Alodine 1201 (for extra corrosion protection) and rinsed that off. After all the parts were hanging dry, I applied a coat of AKZO 2-part epoxy primer. Much easier than I thought, at least in terms of the application. Cleanup is another story entirely... Here you can see the spars and one stiffener hanging out to dry.
After about 30 minutes, the parts were completely dry, so I laid them out for assembly. Oh...by the way, I had made several punch marks on the spars and stifeners before priming so I could get it all back together the way it was drilled. Otherwise, the Sharpie marks would have disappeared...kind of a critical step.
I clecoed the whole thing together, and I hand-squeezed (using the Tatco) the first couple rivets. Lots of work just getting the small Tatco yoke around the flange. Had to tweak with it, and I'm tired as hell.
