While removing the rivets to comply with the HS service bulletin I slipped off the tail of one of the rivets and drilled through the spar. After sending pics to Vans and talking at length with them, their recommendation was to replace the spar and the HS 710 splice angle. I finally took the parts to a Aircraft sheet metal repair shop locally and got a second opinion. They took measurements and sent pics to a structural engineer. They said that the load would transfer to the doubler and new angle and as long as I debured both holes I should be fine. I called Vans back and they basically said that they couldn't perform load analysis for each builder with specific situations like mine and as long as an FAA repair station ok'd the repair then they had no problem with it. Let me say I understand Vans position and am grateful for their builders support helping novice builders like me with issues that arise. My problem with replacing the spar is that I am concerned with further damage as I have already done extensive fiberglass work on the tip. If I mess up the skin taking off all that glass then I'm looking at just building a whole new stab. (Cost of parts vs. stab kit) almost a wash. So I thought I would reach out one last time before making the repair to those on the forum that have expertise with sheet metal repair. I understand the whole just replace it for peace of mind, but am really just hoping to get input from those with an expert opinion.
Thanks,
Thanks,
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