I decided to tackle the baggage/instrument access panel today. This is a popular RV-8 mod discussed and recommended on a number of forums. After reviewing numerous examples I decided to make a fairly large access panel as can be seen below.
You may recall from an earlier post, I reskinned the vertical stabilizer a few months after it was originally completed because I wasn't happy with a couple of my early rivets. The skin was structurally ok but it was marred by a slip of the bucking bar. In any event, I reskinned the skeleton and kept the old skin for scrap. The original stab skin is what I used today to make a doubler for the baggage panel and the removable access panel.
The access panel and the outside edges of the doubler were easily cut with snips but the hole in the baggage panel and the doubler were a little more challenging. Anyway, I cut the holes by drilling the corners with a 1/4" bit and then used a Dremel tool with cutting wheel to make the long cuts. I clamped a piece of angle aluminum on the long straight cuts to act as a guide. On the curved lines I marked the edges with two layers of electrical tape, again to act as a guide. Once the basic cuts were made, I dressed the edges with files, fine sandpaper, and scotchbrite wheel in a die grinder. The Dremel tool works but you have to have a steady hand, go slow and be careful.
The last step was to match drill the new cover panel and doubler to the baggage panel and prepare the nutplates. I am using pan head screws and K1000-08 nutplates all around to secure the panel (no hinge). After some priming the nutplates will be riveted and this little mod will be complete. I think it turned out quite nice. As usual, it took me longer than other builders have advertised.
