October 16, 2007
Rear Spar
Had to order more angle for my Aileron Bellcrank today, so I shifted focus and started on the Rear Spar.  Here are the two channels you start with. One flange is bent in at 11 deg (which is the top), and the other is bent on at 7 deg.  You constantly need to make reference to this while making all your marks and holes. 
The inboard cut-out's.  Tapered on the inboard side.
Started the cut out with a unibit.  There are two holes per  spar that needs cutting out.
Used the Radio Shack nibblers to cut near the line.
Filed to the line and polished up the edges.
Next, we measured and located the rib locations.
Like other people do, we made a rib hole template. We made sure the holes in our template lined up perfectly with the predrilled holes already in the aft ribs.
Rib holes made in both rear spars.
Riveted on the tip angle to the rear spar tip... Does that even make sense ??  While I was doing this...
... My Father was making these small Radius Blocks for the root rib attach angle.  These are made so the nut does not hit the side of angle (we use AN3 bolts for these)... kind of like a spacer.