Today, the task I’m setting out to get the rear wing spars ready for riveting. In the image below, I’m working to locate the TR-W-007F rear spar – aileron attach doubler which is riveted to the rear side of the rear spars. This is a bit tricky as the plans don’t give you much in the way to work with for dimension, and the dimensions they do give, I need to be mindful that my double plate is longer than specified in the plans.
Recall that in modifying the RV-4 wing into the F1 Sport Wing, there are a few improvements made, one of which is this doubler. In the RV-4 plans, the W-407F doubler is only 5 1/2-inches in length. In the HRII plans, the W-7F doubler has been increased in size to 9-inches. And finally, for the F1 the TR-W-007F doubler has been further increased to 11-inches. So again, be mindful of the spanwise measurements shown being measured from the end of the doubler!!
Inboard Aileron Hinge Doubler (TR-W-007F)
In the image below, I located these doublers as best I could with the lack of hard dimensions shown. A big key here to help determine these measurements is to use the #9 and #10 wing ribs aid in locating. In the picture below, you’ll see that I placed a strip of electrical tape in the general area of these wing ribs to make sure I don’t drill anything there.
![](https://f1rocket-hangar.com/wp-content/uploads/2021/06/20201201_113550-940x940.jpg)
Here is a closer picture to show the details of the TR-W-007F doubler.
![](https://f1rocket-hangar.com/wp-content/uploads/2021/06/20201201_113610-940x940.jpg)
In addition to the TR-W-007F doubler, and this being a known week area of the design, several F1 builders have added an additional 0.063 doubler on the forward side of the rear spar to match that of the TR-W-007F doubler. I chose to do the same. Shown in the image below is the additional doubler being located in relation to the TR-W-007F part.
I’m not drilling this yet. I’m going to move on for now and come back a bit later to make sure these doublers are located properly.
![](https://f1rocket-hangar.com/wp-content/uploads/2021/06/20201201_113742-940x940.jpg)
Outboard aileron hinge doubler (TR-W-007E)
I’m moving on to locating the W-407E outboard aileron hinge doublers. These are pretty straightforward and are clearly shown in the plans.
![](https://f1rocket-hangar.com/wp-content/uploads/2021/06/20201201_115812-940x940.jpg)
![](https://f1rocket-hangar.com/wp-content/uploads/2021/06/20201201_120318-940x940.jpg)
Rear Spar Wing Attach Fitting
Moving on the wing root end of the rear spar, I began by drilling #40 pilot holes into both the W-407B and W-407C spar flange strips. Again, in the picture below, note the areas where I added a few pieces of electrical tape to identify where the wing ribs are located, so I don’t accidentially drill unwanted holes.
![](https://f1rocket-hangar.com/wp-content/uploads/2021/06/20201201_123314-940x940.jpg)
With both of the W-407B/C spar flange strips drilled, the next step was to get the W-407D plate clamped and aligned with the spar flange strips, and eventually aligned with the rear wing spar.
![](https://f1rocket-hangar.com/wp-content/uploads/2021/06/20201201_125113-940x940.jpg)
One key thing to getting these spar flange strips properly aligned with the W-407D plate is to ensure the outer dimension of the entire assembly which is 3 3/4-inch. Once getting this dimension set, I had a good place to start for getting the assembly located on the spar web.
![](https://f1rocket-hangar.com/wp-content/uploads/2021/06/20201201_125147-940x940.jpg)
However, as it’s being held together with my little helpers (cleco clamps) this makes it really difficult to get the assembly aligned with the spar. So I match drilled the spar flange strips to the W-407D plate so it can be clecoed.
![](https://f1rocket-hangar.com/wp-content/uploads/2021/06/20201201_142647-940x940.jpg)
Now with the spar flange strips and W-407D plate together as an assembly, it’s much easier for me to locate this assembly on the spar. Once it was located, I clamped it in place so I could begin match drilling all the pilot holes. This process worked really well and gave me a good bit of accuracy.
![](https://f1rocket-hangar.com/wp-content/uploads/2021/06/20201201_144219-940x940.jpg)
Again, before you drill anything, double check all the dimensions. In particular the amount of overhang of the spar flange/plate assembly inboard of the spar which is 2-inches!!
![](https://f1rocket-hangar.com/wp-content/uploads/2021/06/20201201_144301-940x940.jpg)
Below are a few pictures of the match drilling.
![](https://f1rocket-hangar.com/wp-content/uploads/2021/06/20201201_145455-940x940.jpg)
![](https://f1rocket-hangar.com/wp-content/uploads/2021/06/20201201_150055-940x940.jpg)
Once all the pilot holes were drilled, I final drilled them to #30.
![](https://f1rocket-hangar.com/wp-content/uploads/2021/06/20201201_152411-940x940.jpg)
Please comment. I love to hear from my readers. Thanks again for coming along for this ride, you make my work worthwhile.
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