Not much to show on the plane today. I snuck out to the garage for a few minutes and got the doubler plates match drilled to the rear spar. Since I actually knew which end was up tonight, I managed to do it correctly this time! The middle doubler gets a big hole cut out of the center for an aileron control arm, so I used the unibit step drill to hog out some material and then hit it with a file to finish it.
The inboard end of the spar gets two different plates: a forked reinforcement plate and then another doubler at the very end. Easy enough, but I discovered the first manufacturing problem on a part, which slowed things down of course. On the first doubler I used, the holes on the top edge lined up great, but the holes on the bottom were almost 1/16" off. That doesn't sound like much, but when it's a 1/8" hole, that's a big variance. After my screw up the other night I thought I'd double check to see if I was just positioning something wrong. I grabbed the second doubler (for the other wing) to see how it fit. Everything lined up perfectly on that one. I took some measurements and sent a few pictures off to Van's to see if I can salvage it or if they just need to send a replacement part. On the bad piece, one of the holes in the center of the part has a bulge and an obvious hole punch mark that is outside of the actual hole, so I think the tooling may have slipped when they made the part. Thankfully, because the reinforcement plates and doublers are identical from left to right, I can just use the good parts and deal with the bad one when I get to the other wing.
