Step 1.  Okay, here come the mistakes.  Watch out as you examine the pictures here and for the rest of the build.  Make sure you are seeing what you think you're seeing.  I'll explain more below. 

Cleco the VS-1015 front spar doubler to the aft side of the VS-1002 front spar and final drill the holes indicated using a #30.  Remove the doubler and deburr the holes. 

05/26/05  -  45 minutes

Step 2.  Deburr all the holes in the flanges and web of the front spar. 

Now comes one of the mistakes.  Dimple the 4 BOTTOM holes in the front spar and machine countersink the corresponding holes in the doubler. 

When you look at the picture, there are 4 dotted lines from the doubler to the front spar.  Two of those lines go two holes higher up the front spar on each side than where I was supposed to dimple (see where the pencil is pointing).  So, I ended up dimpling 6 holes.  No problem, since I could use the appropriate rivet, but it is just one of those little things that throws you.  Not to worry, another mistake is soon to follow.  See Step 6. 

Dimple the flange holes in the front spar to accept the skin dimples.

05/26/05  -  1 hour

Steps 3 & 4.  Separate the rudder stop pieces and clean them up.  Cleco the stops to the upper of the two VS-1010 hinge brackets and final drill the holes with a #30, remove the stops and deburr. 

The instructions clearly state at this point, "Be careful to cleco the rudder stops as shown, the hole pattern will allow them to be clecoed in reverse."  Note how beautifully correct they are in the picture.  Not for long! 

05/26/05  -  45 minutes

Step 5.  Prime all the parts of the VS in preparation for final riveting and scuff the hinge brackets. 

07/09/05  -  6 hours

Step 6.  Now comes the ultimate cool guy move:  Rivet the rudder stops to the rudder hinge bracket and make sure you do one of them totally backwards, just to prove that you are in fact not the sharpest tool in the shed.  See the picture.  Note the rudder stop on the right.  Needless to say, they are now fine.    

07/12/05  -  1 hour

Step 7.  Reassemble the rear spar, taping shut those holes that are called out not to be riveting.  Make sure the rear spar doubler is facing the right way and have at it.  Rivet away. 

07/12/05  -  2 hours