Page 8-3 has you disassemble a length of piano hinge by removing the hinge pin and then trimming the two halves to the prescribed length. Then you drill 33 evenly-spaced holes to match the pre-punched holes on the AST skin and spar. To drill the holes in just the right place Van's provides a nifty drilling template shown in the picture:
The bottom hinge half is the one I drilled before I carefully read the instructions. The top hinge half is the way it was supposed to be drilled - with one row of holes, not two.
Another 15 bucks down the drain. Sigh.
Warning to other builders: Before you start on this, use a Sharpie to cross out the upper row of holes on the drilling template. If you're a tired it's entirely possible to repeat the above "oops" again. Don't ask me how I know. And if we ever meet - don't bring it up. It's embarassing.
I'm trying to decide whether to include the cost of my screw-ups in the cost tally -- it's not really fair to Van's to inflate the airplane building cost. The CFO says "Yes." "Definitely yes."
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