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Dave's RV-10 Build Log
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Date:  6-21-2017
Number of Hours:  6.25
Manual Reference:  
Brief Description:  Secure Cabin Top at Door Openings

Installed the remaining rivets in the forward tail cone top skin using small bucking bar received yesterday to reach the tight locations. Still had to use 3 Cherry Max rivets in the area above the air conditioner duct nozzle through the baggage bulkhead, as it was impossible to reach the back side of these with a bucking bar.

Installed the screws through the previously drilled holes in the door openings. Had to use super glue to hold the washers to the nuts in order to get the screws in the tight area above the wing spar started.

Added an epoxy/fiber mix (West Systems 105 with 206 slow hardener with 403 fiber) to the space between the cabin top and fuselage door openings. Applied the mix using a zip lock bag with cut corner, then pushed the mix into the gap to fully fill the area using a 1" bristle brush with bristles cut short.

Tightened the screws on each section just after applying epoxy. Had difficulty reaching the nut with a socket in the tight area above the wing spar, due to the conduits and air conditioner hose run just below in the sidewall area. Was finally able to begin making up the nut using a nut driver bit in a small right angle screw driver handle. Then had to move to a deep socket with a universal joint and a 1/4" ratchet to tighten the screw as the nut driver didn't have enough clearance for the length of the screw through the back side of the nut.

One of the front screws on the left door pulled through the fiberglass canopy when tightening. Will have to drill it out once the epoxy has cured, fill the hole with epoxy/fiber mix, and then re-drill and counter sink and install a new screw.
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