We started from a kit the day after Christmas 2012 and should be flying in 8 weeks or less. We are using an older 0200 with 200 SMOH with the firewall forward kit due in a week or so. I can't imagine plans building as I have the patience of a border collie. The 3 of us are in our 50's , 60's and 70 so we just don't have enough years left to thoroughly abuse this plane if we did the slow build. Good luck.
Gary, I got your note about suppliers for aluminum in Baltimore. I have used two different suppliers. For 0.32 thousands and thicker aluminum, EJ Enterprises down near BWI is a good supplier. You have to go their "Metals To Go" group for small orders. For thinner material, I use Access metals in Middle River. They are very accomodating and specialize in small orders.
These are better quality than what comes with the tool. I used the one with the tool and it damaged the surfaces easy. The one from aircraft spruce worked great. It fits the heads better.
I practiced on about 50 holes. I set up the same thickness for practice.
The jig set the spar height. I drilled the lower spar cap and clecoed. Then I measured the spaceing for the spar and drilled the the upper spar cap at one end. Made a jig of that spacing. The moved down the spar and drilled the caps between the jig. The next spar will be the same as the first. I pre drilled my spar caps.
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