DATE: 10-18-2024 TIME: 2:30
I spent all of this time assembling the two tip ribs, counterbalance ribs and counterbalance skins.
In my kit, delivered in August 2022, the counterbalance ribs and the tip ribs were laser cut parts so I had them replace. One of the number of delays I experienced as a consequence of Van’s Chapter 11 filing.
The original E-904s and E-903s, although laser cut, were not fluted. The replacement, not laser cut E-904s were heavily fluted between each hole and the E-903s, while not fluted, arrived with the last 8 or so holes toward the rear, dimpled. I’m not sure why they only dimpled those 8 holes, nor why they fluted all of the E-904 but none of the E-903.
The net result was that in order to get the counterbalance skin, E-913 “match hole drilled”, skin to properly line up with the E-904 and E-903 I had to press out a lot of the fluting in the E-904 and flute a fair section of the E-903s. Even then it was a strain to get them to cleco together, but it would have been impossible without these adjustments.
I final drilled the parts once they were assembled and then separated the E-1022 shear clips for which I used my cheapo bandsaw from Harbor Freight. I then ran them on the 3M medium grit buffer wheel to smooth out the edges.
