Horizontal Stabilizer Spar Final Prep and Part Deburring!

 Finished prepping the HS front spar by match drilling a few more holes.

 Then reaming the same holes to final size.

 Countersinking eight holes on the web of front spar.

 And then countersinking nine holes on each side of the front spar, both flanges.

 Side one....

 Side two...

Then I got to work cleaning up the edges of the spar doublers.   These things are rough out of the gate.  The vixen file is a huge help.

 Then I took the vixen file to the flanges of the rear spar.

 Deburred the holes of the rear spar doubler.

 Deburred the holes of the rear spar. (Only the holes that have been match drilled to something at this point)

 Found my old deburring tool that helps deburr long straight edges.

 It has a hardened V Notch tool.

 And there is a different tool that you can spin around the inside edges of holes and get them as well.

 Here is what that bit of tooling looks like.

 Next I used the cut and polish wheels to do the final smoothing of the edges and the holes.

 Then I deburred the holes of the front spar doubler.

Then I deburred the holes of the front spar mounting brackets.

Then I deburred the holes of the front spar doublers.  There are two of them.

Then the holes of the front spar itself.  (only the holes that have been match drilled to something at this point)

This is how I get to the inside of the spar flanges where the drill motor gets in the way.  This keeps the deburr bit as straight as possible to the hole.

Next I took the vixen file and cleaned up the edges of the front spar doubler.

A small rounded back file is used for the large radius corners.

Used the cut and polish wheel to do the final smoothing.

Used the large cut and polish wheel to deburr both the front spar caps.

Then I took the vixen file and cleaned up the edges of the front spar flanges.

Then I used the deburr tool to clean up the holes of the front spar.  Both sides.

And the cut an polish wheel to do the final finishing.

This small pile of large parts represents a ton of work!  There are a bagazillion holes in these parts that have been match drilled, deburred etc.  I am going to prime this pile tomorrow and rivet them both together before moving on.  For some reason this is how the directions are written so there must be a good reason even though it is not obvious.