To get a jump on things I started working on the rear spars. Mainly just doing some of the trimming that is required before really getting into it. I bought a new bandsaw and was able to test it out as I trimmed the excess off the fuselage attach point on the spar doublers. (love the bandsaw, wish I had it earlier - Craftsman 10 inch) This worked out well as I matched up the two doublers and match drilled it straight into scrap wood. Then used the bandsaw to cut through both at the same time. One thing I thought of after the fact is that I could have used the doubler as a template and traced the outline onto the other doubler before feeding it to the bandsaw. My measurements turned out pretty accurate, but this might have helped make it quicker.
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After tracing the pushrod hole from the spar onto the aileron attach doubler, I used a step drill to punch out the holes in the doubler plate. I then put a grinder in the drill press on high speed and it shaped the hole up right away.
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Here is one picture that I will be asking vans about. It seems both rear spar center doublers lean to the right when looking at them directly from the back. Not sure if this is a problem in manufacture, but I will contact Van's as well as talk to the guys on the forums. - UPDATE - From the forums, it seems this is no big deal, as long as hole/edge distance is satisfactory. I measured it up and each rivet hole is far enough from the edge. So looks good and onto priming and assembly..
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