Step 1- Rivet together the HS-1002 Front Spar, the HS-1007 Front Spar Doubler, the HS-1013 Front Spar Caps, and the HS-1008-l and-R Front Spar Attachment Brackets using the rivets shown in figure 1. Install only the rivets shown in the figure. Tape over the open holes to keep yourself from accidentally riveting them. (note I bucked most of the rivets with a bucking bar, all of them except along the spar flange which I used the squeezer. The problems with squeezers is on the Long Rivets(-7,8,9's) there is not enough throw to form the head, even the manufacturer mentions it it the instructions for the pneumatic squeezer so it works great on shorter rivets but you probably will need to go back to basic bucking on the long rivets.)

Step 2- Install AN426AD3-4.5 rivets into the nine holes in both flanges of the HS-1013 Spar caps. These are the holes which were countersunk in the spar flanges on Page8-5, Step 7 (Note- again here the squeezer works great on the shorter rivets)

Hit the area where the rivets went with some good primer

Top

Smoothing the edges. We cut with and band saw, cut for us, was easier for us with band saw.

Measuring for cut

Step 3- Locate four of the HS-1004 Inspar Ribs. Remove the portion of the top and bottom flange, shown in the upper rib drawing of Figure 2, from all four ribs.

The ribs, and parts for the next steps

Step 2- The two HS-1004 Inspar Ribs which had the four flanges trimmed on Page 8-6, Step 4, need to be modified further. Use a hand seamer to bend the aft flange open by 9 degrees as shown at the bottom of Figure 1. The forward portion of the rib must also be bent 9 degrees as shown at the top of the figure. This bend can be accomplished by holding the forward portion of the rib against a solid surface and pressing down along the bend line. The part will bend along the bend line, between the two notches shown in Figure 1

Step 3- Deburr the edges of the HS-905 Nose Ribs. Flute if necessary, the curved flanges of the ribs until the holes in the flanges are in a straight line.

Radius the corners at the forward end of the nose rib flanges see Figure 2) to prevent them from making small dents in the skins when the ribs are installed

Step 4- Put aside all but two of the HS-905 Nose Ribs. Open the bend in the aft flange of these two nose ribs by 9 degrees.

Cut a hole in the web of both nose ribs using the dimensions in the figure. The hole is used for routing the trim cables.

Step 5- Fabricate four cradles out of 3/8' (min) plywood to hold the horizontal stabilizer during construction. Make a template, used to trace the stabilizer's cross section, by clecoing together a nose and Inspar rib. The 3/16" inch tooling holes in the ribs can be used to square the ribs with the plywood. Offset the trace about an eighth in to allow for the thickness of the skins and duct tape liner.

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