Finally, some visible progress! I match-drilled the left HS frame, then deburred the resulting holes. Those 12-inch #30 drill bits I bought eleven years ago finally got some use. The frame was reassembled and with Ellen’s help, the skin was fitted to it. I found that this process is much easier if you can get one or two clecoes in the nose ribs, since that’s where the fit is worst initially.

I’m so happy to have something that resembles an airplane part that I’m throwing in another picture. Note that I’ve slipped in the HS-405 just for grins. I haven’t drilled its forward flange holes yet, and won’t until the new HS-404s arrive, are trimmed, and are test-fitted to the -405s to verify proper edge distance on the web holes.

The only slight hiccup in this process was getting the HS-707 nose rib (the one at mid-span) holes to align with the skin. This rib fits into the leading edge at an angle, and the rib flanges won’t fit easily into the skin. If you’re not there yet, take your time and try to get the flanges as aligned with the skin as possible as you insert the frame into the skin.

Pictures are courtesy of Tracy Murphy, generous co-worker and friend, who lent me his spare digital camera while the Post Office finds mine. Movie of the day was “Goldmember” – yeah, baby!