Brief Description: Assembled and drilled roll bar.
Clecoed the roll bar parts together with #30 and #40 clecos. Used all my #40's! Temporarily installed Roll Bar Bases and Roll Bar Attach Plates to the fuseage assembly, which is still up on its side. Then slipped the roll bar into the bases so when I match drilled the parts they would all be lined up with the bases the way they will need to be during final assembly. Did this to avoid the width problems some other builders have reported.
Match drilled all the #40 holes to #30 holes, starting from the middle of the assembly and working out in both directions, changing from #40 clecos to #30 clecos as the holes were drilled. Then removed the entire assembly, and took it apart to deburr all the holes. Tried to do a real good job of deburring, because I want all these parts to be very tightly riveted together for strength. Then installed the countersinking tool in the electric drill, and clamped that in the bench vise. This made it relatively easy to hold the roll bar frames against the tool and get good consistent countersunk holes.
Now that the drilling and countersinking is done (nearly 200 holes) I will prime all the parts, then reassemble with clecos, and once again temporarily attach to the fuselage. Then I'll rivet the whole assembly together while it is being held exactly where it will go in final assembly.
Late in the day the care package arrived from Van's, so will suspend work on the roll bars at the end of Page 24-02 and return to finish the fuel and brake systems. Also need to start painting the interior while it is still nice and accessable.
