Saturday, April 8, 2000 
8:30 A.M.
I arrived at 8:30.  Took pictures of the tail kit which arrived four days ago.  Size of crate was 49.5" x 29" x 5.75".  Inventoried all of the parts, inspected materials.  All was ok.  Set contents aside until ready for them.
     

9:00
These are the strut mounts looking at the leading edge, then at the trailing edge from in front of the leading edge. Note: nuts are not yet tightened.
  

9:20
We noticed there was no clear measurement documented for drilling the inside aileron hinge.  We marked trailing edge spar for outer four aileron hinges.

9:52
Here we are drilling aileron hinge holes. Note: The hole for the outermost hinge did not align up perfectly with the factory drilled holes.  The factory holes were slightly below the apex of the tube.

10:00
Drilling the inside this tight spot required a special 90 degree angled drill bit tool.
 

10:15
The kit came with hinges, bolts, locking nuts, but did NOT come with washers as pictured.  After doing some research, Excalibur Aircraft realized the washers were supposed to be in the package and immediately shipped me a full supply of the washers PLUS some bolts to replace others that they felt were not long enough!  It is really nice working with a company that not only listens to you, but will take your suggestions and use them to improve their product.  Everyone wins!  This is just another great example of working with Tom Karr and the Excalibur Aircraft team.
  

10:50
Aileron marked for drilling.  Then drilling.  Note: drilled inside, then outside and NOT straight through at once.  This insured a perfectly level alignment of the holes.
   
 

11:10
Aileron hinge attached (nut not yet attached).  Aileron attached to wing.
   

11:20
Mike looked up the rivet spacing for the ribs in his Poly-Covering manual. The Excalibur Factory says rivet every 4 inches. But, due to the Vne being 100MPH and the engine is behind the wings, the recommended spacing should be every 3.5 inches. We marked the first rivet hole on the two outermost ribs then used a chalk line to mark the rest.
  

11:40
Drilling the ribs.  Twelve holes in fifteen ribs = a whole lotta drilling!
 

1:15 P.M.
Finished for the day.