Step 1.   Rivet the remainder of the E-1001 skins to the flanges of the E-903 outboard tip rib.  These are the three holes, each side, that are left to do.  No hole yoke will work, even for the last two rivets at the tip. 

04/07/07  -  30 minutes

Step 2.  Rivet the shear clip to the close out tabs.  Put a rivet in those two rivets and one in the hole that stands alone.  Use the CS4-4 blind rivets. 

04/07/07  -  15 minutes

Step 3.   Make a slight bend along the leading edge of the top skin to help it lay flat after you've rolled it and are riveting it to the bottome leading edge skin.  I think I did this for both skins.  I wasn't paying attention.  You only need and want to do it for the top skin. 

04/08/07  -  15 minutes

Step 4.  Roll the leading edge of both top and bottom skins.   I was lucky.  Bruce Breckendridge lent me his PVC pipes already drilled and ready to go.  I just clecoed the on, used duct tape to secure the entire edge to the pipe, gave the skin an initial roll, then took off the clecos, added more tape, and gave each a final, tight roll.  This is not 1-1/4" pipe that the plans call for.  It's 1".  Works fine.   

04/08/07  -  2 hours

Step 5.   Cleco the top skin on top of the bottom and final drill (or ream) the holes with a #30.  Watch out, here.  If you don't square up to the hole, you can elongate the back hole.   I then took out all the clecos and deburred the holes, which they don't say you have to do, but did them anyway.  

04/08/07  -  1 hour

Step 6.  Rivet the leading edges together.  Be careful with the rivets on each of the ends.  The ends tend to curl and not let the rivet set correctly.  I drilled out two that simply wouldn't cooperate.     

04/08/07  -  1 hour

Step 7.   Skipped for now.  I'll finish this when assembling. 

Step 8.   I did the lead weights a few days ago.  Use the band saw and the large file.  They mean it when they say to remove the amounts shown.  Don't forget to wear goggles and a mask.  Also, clean up that band saw!

03/31/07  -  1 1/2 hours

Step 9.  Attach the weights as shown in the plans. 

04/08/07  -  30 minutes