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Old 09-02-2018, 11:47 AM
Girraf Girraf is offline
Join Date: Dec 2017
Location: Southern Maryland
Posts: 132
Default Day 1 - Already an issue

First day of many and already need an opinion. I was test fitting the horizontal stab rear spar reinforcements and noticed that the 2 pieces that butt up together to form the spar don't exactly line up. They are about .035" askew. When I lay them end to end without the reinforcement, they are exactly the same size, but as soon as I cleco the supports in there, the parts shift. Is this normal variability in production? It looks to me as though the holes that are punched in the spar halves are in fact just slightly off from eachother.

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Last edited by Girraf : 09-02-2018 at 12:38 PM. Reason: Removed Links
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Old 09-02-2018, 12:07 PM
BigJohn BigJohn is offline
Join Date: Nov 2008
Location: Gloversville, NY
Posts: 1,587

Not getting pictures.
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Old 09-02-2018, 12:17 PM
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N804RV N804RV is offline
Join Date: May 2013
Location: Mount Vernon, Wa
Posts: 621

Can't see your pics.

The tapered spar reinforcements have to be radiused to fit into the flanges in order for the match holes to line up. Also, all tooling marks and extra material needs to be filed off. I used a 3M deburring wheel on a bench grinder for this.

With the proper radius and all the holes lining up, you will still have a small gap, end to end between the spar halves.
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Last edited by N804RV : 09-02-2018 at 12:19 PM.
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Old 09-02-2018, 12:33 PM
Girraf Girraf is offline
Join Date: Dec 2017
Location: Southern Maryland
Posts: 132

At the time these photos were taken, the appropriate edges have been broken to get them lying flat inside the spar, all 4 ends radiused around the end holes, but only 1 has been fully polished. I don't believe the offset is caused by the incomplete finishing work on the reinforcements.

When I test fitted them, I had clecos in end holes as well so there shouldn't be any twisting going on.
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Old 09-02-2018, 01:10 PM
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RV7A Flyer RV7A Flyer is offline
Join Date: Jul 2013
Location: US
Posts: 2,209

It's metal...bend it to make it fit and square up the flanges.
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Old 09-02-2018, 06:43 PM
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longranger longranger is offline
Join Date: Mar 2007
Location: 45G, Brighton, MI
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If you have properly radiused the bars to fit the radius of the channels (in this case it takes more than just breaking the edges) and have more clecos outboard make sure they are lined up properly, then one or the other of the spar channels is mis-bent or mis-punched. It’s rare to see that from Van’s but does happen occasionally. I had it happen with an aileron spar. They replaced it no questions after I sent pictures.
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Last edited by longranger : 09-02-2018 at 06:46 PM.
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