I had this discussion with our PFA engineers in UK, and they told me that
any unwanted blank holes in the spar should be plugged with a bolt shank.
The theory being that a wooden dowel could compress and weaken the spar..

Long time agooo!
Regards to all ,
Mac

On Tue, Jan 26, 2016 at 12:13 AM, Dave Acklam via KRnet <
krnet at list.krnet.org> wrote:

> Thanks for all the replies....
>
> I now get what everyone means by 'shear joint', and that one should NOT
> weld anything unless you want to go through a whole hell-of-a-lot of extra
> work fixing the metallurgy of the resulting part.
>
> So far, the choices everyone has posted seem to boil down to:
>
> 1) Make new WAFs for one side using same-thickness strips of 4130, using
> the old ones as a template, then drill the main bolt-hole for the
> pin/attach-bolt based on where everything lines up.
>
> 2) Move the WAFs around on the spar, using dowels to plug the old bolt
> holes.
>
> My WAFs aren't really 'off' on the spar (both my old spar & my new wings
> are fully complete right now - the wings were slightly damaged in transit
> but nothing irreparable), and the holes appear to be the right diameter.
>
> So it would seem that making 'new ones' from strip steel would be the best
> choice, although I am open to more ideas.
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