A local RV-8 builder dropped by this afternoon to inspect and discuss the fit problem I have with the cockpit rails. After some dicussion we decided the rails could be match drilled "as is" without creating any structural issue (plenty of edge distance on the longerons but outside edge not flush with the mid side skins). The alternative is also viable and that is to make the edges flush and match drill the rails to the upper flanges on the center bulkheads elongating the holes but adding a doubler plate on the bottom of each flange.
I opted to make the edges flush and add the doublers beneath the bulkhead flanges. This approach looks better, the edges are completely flush, the doublers are hidden, there is no structural issue, and the cockpit width for future mounting of the canopy bow is correct.
I began by drilling the rails to the upper longerons and then match drilling the rails to the center section bulkhead flanges and their doublers. I am happy with the results.
