Posted by Time consuming tasks today. Started out by fitting the two small aft bulkheads into the structure. Because of a little interference between my J-channel stiffeners and the flange cut-outs of one of the bulkheads, I had to spend a bit of time filing a couple of the cutouts about 1.5x width to compensate. Adequate hole/edge distances were maintained.
Then it came time to fit the left J-channels into the frame, and cleco the left skin on to the structure. This went very well except for the very aft end where the fit was really tight and the holes were just slightly off. Had a heck of a time trying to get things aligned and clecoed, in some places going through three pieces of aluminum. A handy trick I ended up using was getting a little ice pick through all the holes and using that to pull everything in alignment.
Then came the time-consuming task of match-drilling the ~300 holes along the J-channels on the left skin. End results was great.
I also took the opportunity to jump ahead try one of the longerons for size. It was perfect, lining up the bend apex to the right spot, the angle aluminum lined up with the top of the skin perfectly. Just a little interference with the pre-cut notches on the bulkhead pieces that need to be fine tuned.
Builder's Log 