Jessen RV-10 Builder's Log
Keep It Simple; Keep It Safe
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Step 1.  F-1006 sections.  Deburr the edges and final drill where appropriate.   Can you say, "BORING" as in dull, tedious, uninteresting, mind numbing! 

01/08/06   -  2 hours
Step 2.   Cut the j-stiffeners to length.  Be careful to cut the large lengths first out of the large stiffeners so you don't end up using a long piece for a short one.  Be sure to leave each a mm or two long to allow for deburring the ends.

11/15/05  -  1 hour    Cut Off Wheel

Step 3.   This is a 2-part step.  First, after you cut the j-stiffeners to length, cut the ends at a 45 degree angle inward.  The picture in the plans takes a couple looks to get the orientation correct.  The trick is to begin the cut at the base of the "j".  Do not cut the flat part, which is the part that gets riveted to the skins. 

01/15/06  2 hours    Dremel

The second part is one of those grin and bear it deburring steps.  It's so deceptive to have a short sentence in the instructions, " Deburr the edges."  Three words takes you three days to complete.  Fortunately, beyond the tedium, it's easy to do.  Using the scotch brite wheel, knock off the shear marks from all edges and get them reasonably smooth.  Then mount the j-stiffener in a vise or some similar setup and proceed knock off the edges with a V tool, sand the edges with 220 grit paper, a finalize the deburring with the maroon scotch brite pads. 

There are 12 j-stiffeners.  Each one takes 13 discrete steps.  That's 156 steps to get these puppies in shape.  You don't want to turn around and look at all those wing parts midway through the process.  But, should you make that mistake, just go grab a beer and listen to some jazz or something. Try not to think about all the hours ahead. 

01/20/05 - /1/22/06  -  6 hours

       
Step 4.    Finished the j-stiffeners today.  The last step was to draw a rivet line 5/16th of an inch from the edge of the flat surface and 3/16ths of an inch from each end.  The marking tool shown made this step very easy and quick. 

01/22/06  -  20 minutes

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