Well, tonight we had to do something we should never of had to do. Van's shipped us a main wing spar that was underbent. You can see that the ribs and the spar flange weren't flush from the last set of pictures. What this meant is that we needed to essentially reverse the bend on the main spar. We were hoping that we had done something wrong and that a quick fix could be made. However, it turns out that the mistake was Van's. The latest edition of the RVator (the bi-monthly journal from Van's) had a similar story of an RV-9 builder with the same problem so the fix was really clear. Anyways, we're not happy we had to spend a night fixing a problem that would've been much much easier to get right in the first place.
The "good" flange (bent inwards)
The incorrectly bent flange (bent outwards)
Scott using the hi-tech bending tool to slowly bend the spar flange
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