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Dave's RV-10 Build Log
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Date:  2-8-2019
Number of Hours:  6.75
Manual Reference:  
Brief Description:  Tunnel Side Access Install

Unpacked, inventoried and put away the hardware received from Aircraft Spruce.

Began the process of installing the side access panel into the tunnel to alllow easier access to the electric boost pump, fuel filter, and fuel flow transducter. Using a kit purchased from AirWard Inc for this as it includes a pre-punched reinforcing ring and cover plate which makes the job easier.

Drilled out 11 pulled rivets holding the floor to the tunnel. Clecoed the reinforcing ring to the tunnel using these holes, and then match drilled the #40 holes for mounting the ring to the tunnel. Drilled the larger corner holes for the cover plate mounting as well. Removed the ring and deburred the holes in the ring and tunnel side.

Clecoed the cover plate to the tunnel side using the larger holes drilled for this. Drew a cut line around the cover plate using a sharpie.

Drilled out the 4 corners and enlarged them with a step drill.

Determined that there wasn't enough room to cut out the cover plate hole using a sabre saw, so used a 1.5" metal cutting disk in the dremel tool to make the cut in the tunnel side. This left an opening that was rough and not very straight, so cut well inside the cut line.

Began cleaning up the cuts forming the opening using files. Tried using a 2" ScotchBrite wheel in the pneumatic drill, but it didn't work well. Found that I could use a small 60 grit sanding drum in the dremel to help open up the hole, along with the random orbit sander with 60 grit pad to help make the cut line straight.

Dimpled the ring for installation of the plate nuts, and then installed all the plate nuts for mounting the cover plate to the ring using the furnished AN426AD3-3.5 rivets. Counter sank the cover plate for the mounting screws.

Installed the cover plate onto the mounting ring with a few screws. This allowed me to insert the cover & ring into the inside of the tunnel and hold it with clecoes in order to judge the areas of the opening that need to be removed to fit the cover. Marked these areas
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