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Double doublers? It seems I made a mistake. The earlier picture of the countersinks in the doubler would reveal a problem to the sharp eyed observer. The countersinks were way to deep. I have done plenty of countersinks before and I’m still scratching my head as to how I got them wrong, but as soon as I did them all I knew they were wrong. I had done a test piece using my own methods derived from how I did them in the Sonex and the test piece was correct. End result order a new piece from Van’s. Sonex gives you the outside diameter of the countersink hole. Van’s doesn’t do it that way so I referenced the Sonex sizes which should work and made a sample. Somehow from sample to finished piece I screwed up. Anyhow I reset the tool and used the Van’s method which was easier and gave the same result as my earlier sample piece. I then clecoed the rear spar, the old and new rear spar doublers all together and final drilled all the holes into the new doubler. I of course had to clean up the new doubler just like I did the old one. For the outside edges I just clamp the piece in a vice and use the vixen file to quickly smooth out all the edges. The interior of the lightening holes takes a little more work. I use a round file but then use a small scothbrite wheel on a drill to polish. Pictures three and four show before and after.
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