Horizontal Stabilizer

First step in assembling the HS rear spar is to taper the spar stiffeners (HS 609PP).  This is the first significant machining done on the kit, and I found that it worked best to use a 1” benchtop belt sander for the job.  Once the approximate shape was obtained, I used the bench grinder w/ scotchbrite wheel to smooth out the edges. 

In preparation for assembling the rear spar, you must first rivet the elevator bearing assembly together.  The plans mention the possibility of priming the bearing surface.  To do small jobs like this, I got a couple of cans of the Sherwin Williams self-etching primer (GBP-988).  It seems to go on much easier than the P60:

Make sure that you tape over the bearing holes prior to painting, as you do not want to get paint in the bearing surfaces.  Close-up of some of the first rivets set:

Next you will go about tapering the HS-710 and HS-714 front spar reinforcement angle.  To get the 6 degree bend in the angle, you will use the bench vise and your strenght.  To verify the correct angle, one can create a template out of cardboard.

To make room for the stiffener angle, you will have to notch the HS 404 nose rib.  I used a dremel tool with a cutting disc to do this, and it seemed to work great. 

Because of the required notch, you may not have quite the 1.5x edge distance on the last two holes.  I talked to a lot of builders about this, and they all seemed to have the same thing.  There is a lot of rivets and re-inforcement in that area, so the consensus is the limited distance is acceptable in that area.  Part of my rationale is that I would not be able to get it any better even if I ordered more parts.

HS skeleton clecoed up and ready to rivet: