3/20/2007
I decided that I over-thought, and over-engineered my wood spacers that I made last night. It occurred to me today that I didn't need these big sandwiched particle board spacers that may or may not fit right. Why not just cut a two by four in four sections of 1 7/16"? Hmm. That's easy. So, I did that, then fit the spacers between the 704 halves.
Then I found the F-704H side channels and deblued/deburred those. Then they were cleco'd to the 704 bulkhead and I finished drilling the holes.
After that, I grabbed the laptop and did some searching on the four holes that are countersunk in the 776 skin and 704 flange. Van's made a special instruction announcement (it's in the FAQ section on Van's website in PDF format) about this part, as it is confusing at first. I printed that and read it several times. That, along with a search on VAF gave me what I needed to get the picture.
I numbered the holes so there was no mistaking where the holes not to be dimpled were. This countersink goes thru the 776 skin where it is "over countersunk", and slightly in to the 704 flange. This is totally acceptable for this part.
Van's gives you the option of countersinking the skin/flange all the way across, but I prefer NOT to remove metal wherever possible, so I'll just dimple the flange and two skins that overlap here. These holes are countersunk to keep the inside flange flat for the floor stiffeners that will be installed later.
So to finish out the night, I simply countersunk those four holes.
All this comes apart to prep for priming and riveting in the next word session.
2.5 hours