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Gary's RV8 Construction Log
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Date:  8-14-2010
Number of Hours:  1.00
Manual Reference:  
Brief Description:  Z Brackets ... cleco fuel tank skin

I wanted to see how the fuel tanks sat on the Z brackets before continuing to drill them so I elected to cleco it together quickly - it ain't quick, this skin is THICK!

I eventually made myself two "awls" from a pair of 3" nails. I stuck the pointy end into my battery operated drill and ground down each head on a bench grinder whilst spinning it in the drill - this ensured that it was fround down to be perfectly round. With the head removed, I turned it around and ground each one down to a nice gradual point whilst spinning it in the drill. Still in the drill, I then smoothed them out to a nice satin finish on the scotchbrite wheel - was actually very quick and easy - well worth the trouble as it made the fitting of the skins substantially easier.

I'd start by manually manipulating the skin and a rib until such time as I could place the awl (albeit at a bit of an angle) through the skin and the rib. Trying not to align the skin by "manipulating" the awl in an attempt to minimise damage to skins or ribs, I opted to align the skins mearly by pushing the awls in deeper and deeper. Obviously a little bit of "manipulation" (i.e. using the awl as a lever) is necessary but I tried to keep it to a minimum. Using both in unision and moving down towards the leading edge, I placed clecos along the leading edge on one side and then the other, 1 rib at a time moving towards the rear on both sides simoultaniously, only moving to the next rib after having sufficiennt clecoes in both side of the first. The awls helped tremendously - I'll definitely hang on to them and use the to assist in any alignment issues again in future
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3

3" nails turned into "awls"

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Skin clecoed toribs - phew!

Skin clecoed toribs - phew!

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