Step 1.  Deburrrrr the edges of all remain parts.  Oh, the joy. 

05/20/05  -  2 hours

Step 2.  Assemble the VS skeleton.  Kinda cool to see something taking shape. 

Final drill all holes common to all the skeleton parts with a #30. 

05/20/05  -  1 hour

Warning:  At this point you should consider radiusing the edges of the nose ribs.  If you don't, and this step is not given in the plans at this time (it is in the HS section), you will put dents in the skins as you struggle to get them to fit.  Go to the HS section of the plans and check it out.  Not hard to do and worth the trouble. 

Step 3.  Remove the vinyl from the inside of the skin and cleco to the skeleton.  

I decided not to remove all the vinyl.  Instead, I used a soldering iron and removed strips of vinyl enough so that there was nothing in the way of the ribs.  I think doing this does you nothing.  You won't scratch the inside that much if you're careful, and the process of removing the strips of vinyl on the inside is exceedingly tedious.  On the outside, that's different.  It's easier and you will scratch it more given all the handling.  Once completed, remove all vinyl and hang it up.  Keeping the vinyl on may cause corrosion if it takes years to complete the plane. 

05/20/05  -  1 hour

Step 4.  Final drill all those holes common between the skin and the skeleton with a #40 drill.  After finished, remove the skin and deburr the holes.  I used the Cogsdill deburring tools at this time.  You don't need these, but I highly recommend you get them.  See the tools section. 

05/22/05  -  2 hours

Step 5.  Mark the empennage fairing screw holes per the plans and leave these alone.  That is, don't drill or dimple them at this time.  

05/23/05  -  30 minutes

Step 6.  Get out the ol' C-frame dimpling tool and begin whacking away.  Dimple all the holes in the skin, except those you marked.  There will be some holes in near the leading edge that you'll need to use a pop rivet dimple die set.  You can get these at Avery's or the other supply houses. 

05/23/05  -  2 hours

Step 7.  Remove the ribs and deburr all the holes.  This goes fast.  Remember to leave alone the ones marked in Step 5. 

Then dimple all the rib side flange holes as indicated.  Again, easy to do, just don't forget which way the dimple goes! 

05/23/05  -  1 hour

Step 8 & 9.  Machine countersink the flange holes as indicated in the VS-1003, then disassemble the rear spar and deburr all the holes.   I'm deburring the front spar in the picture, but you get the idea. 

05/24/05  -  3 hours

Steps 10 & 11.  Dimple the flange holes in the VS-1003 rear spar as indicated.  Then final drill the #12 holes in the hinge plates and deburr.   Again, the picture has the wrong spar, but you still get the idea.  I just hadn't gotten used to taking pictures of each step at this time. 

By the way, a tripod and timer comes in handy with these cameras.  Most of the time I'm not actually doing anything other than holding still because of the slow shutter speed.  I found that taking pictures with the flash wasn't as good as using the shop lights.  Longer shutter speed, but better quality picture. 

05/25/05  -  1 hour