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The Redheads RV-7A Build SIte
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Date:  9-27-2009
Number of Hours:  1.50
Manual Reference:  Section 7
Brief Description:  Preparing the Left Wing Spar Caps

The plans call for installing the nutplates prior to countersinking the holes. But I wanted to countersink without the nutplates in place so I could prime the spars before riveting the nutplates in place. Countersinking the 3/32 rivet holes was easy because the spar caps were thick enough that the countersink pilot could still be engaged with the hole. This was not true for countersinking the scew holes. The flanges are too thin to support the pilot hence Van's recommendation that the nutplates be installed - the threaded portion of the nutplate will support the countersink pilot. So I made the tool pictured in image 2. I utilize clecos in the nutplate rivet holes plus the drill bit I used to drill the to be countersinked screw hole to locate the tool and then I use a pair of small vice-grip clamps to hold the tool in place as shown in image 3. Made countersinking the screw holes much easier.
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Drilling Fuel Tank Support Nutplate Holes

Drilling Fuel Tank Support Nutplate Holes

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Tool I Made to Help Countersink the Main Spar Fuel Tank Support Holes

Tool I Made to Help Countersink the Main Spar Fuel Tank Support Holes

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Tool I Made to Help Countersink the Main Spar Fuel Tank Support Holes

Tool I Made to Help Countersink the Main Spar Fuel Tank Support Holes

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