Practice Kit 2 - Control Surface

Yesterday I completed the tool box practice kit which was a HUGE confidence builder with using all the new tools. Today after some house chores, I went off to the aircraft factory (aka garage), and started on the second practice kit.  On this kit I back riveted for the first time and experienced some tight space bucking.  The instructions were understandable.  No mistakes, or smiles anywhere.  The leading edge was rolled using a 1" PVC pipe at first.   The 1" pipe roll was too big leaving a very big gap between the two skins and not round enough for me.  re-rolled with a 3/4" PVC pipe and the roll was tighter and rounder closing the gap.  the skins still need to be pushed together some to match drill the bottom skin.  After some pop rivets all was done.  The aft top and bottom rivets were too tight to squeeze or buck normally.  It requires the specially made tool before starting this control surface kit that I skipped.  Yeah.  No more skipping steps.  There is a reason for vans madness.  Here are a few pictures of the process.

The kit as sent from Vans.

Clecod and ready for match drill

Spar and ribs clamps ready to match drill.

Bucked forward spar to skin.

The tight aft rib rivet (not riveted here yet) requiring the special tool to be made prior to starting this kit.

Leading edge rolled and popped.

Finished product.