Flap-brackets are final-drilled and their associated ribs have been match-drilled. The torque tube support assemblies are ready. Conduit holes are drilled in the ribs. Most holes needed to be enlarged, however some holes needed to be created. Using a punch is not the way to go as it deforms the web. So I used a smaller bit, about 1/32", to create the hole, enlarged it with a 1/8" then used the unibit for final-sizing. Some of the conduit holes are 1/2" so using the hand deburring tool was a non issue on these larger holes. For the smaller holes, the 400 grit sandpaper worked fine.
Next was removing the bolts from the web of the spar. Some of these came out easy, others were extremely challenging. Almost as though the hole they were sitting it wasn't big enough. With the bolts removed, the ribs get cleco'd onto the spar so that 1) the #30 holes in the spar web and rib forward flange can be final-drilled, 2) the forward flanges of the ribs can have the bolt holes match-drilled with a #12 and 3) final-size drill the #40 holes on the rib tabs (which I had done previously since I looked ahead at the plans). Using a #12 bit to start a hole on the forward flanges is not a good idea. So I used a #30 bit to start the hole and final-sized it with the #12.
Cleco'ing in the ribs on the right spar.
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