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Todd's Web site
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Date: 6-28-2010
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Number of Hours: 2.00
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Manual Reference: 8-28/29
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Brief Description: Drilling Fuselage Skins #9
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Well I called Van's today and spoke with Gus Funnell. I sent him several pics, and he called he answered me back a few hours later. There are a few options, but his solution was to just squeeze it all together then file a little to drift the holes over as much as possible, then drill through to align the holes again. He said it wasn't a problem if some or even all the holes in the rail/weldment are elongated. The weldment will still held by 16 AN3 bolts below and the canopy tracks will be over the top of the holes, so on the finished airplane it will all be concealed anyway. Any loads are going to be upward, or forward, not tending to pull the screws down through the rails. And as far as the edge distance concern, he sent me a pic a QB kit where the rearward hole was pretty much as close to the edge as mine. That was their engineering disposition on the matter. It bugs me that it's not right but I guess I can live with it, besides it's certainly the cheaper route. I went ahead and worked on the tailwheel mount and aft bottom skin while I mulled it all over.
-Match drilled the rudder stops
-Removed the F828 bottom most aft skin (where the tail wheel mounts) and bulkhead F812.
-Cleco'd the WD409 tailwheel mount to the F812 bulkhead
-Layout the location of the WD409 on bulkhead F811.
-Cleco'd the F812 and WD409 back onto the fuselage.
-Made shims for the tail wheel mount per the plans.
-Clamped the tail wheel mount (WD409) to the F811 bulkhead and match drilled it using the holes in F811 as a guide.
-Made a template of the cutout required for F828 aft bottom skin to accomodate the WD409 tail wheel mount. Traced it from the full size drawing onto paper, then transfered it to skin. Rough cut with the bandsaw and then used the demel, then filed and sanded. Fits nice.
-Final drilled a 3/4" hole with a unibit in the bottom of the F828 aft bottom skin per the plans.
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Tailwheel mount clamped into place with spacers on the F811 bulkhead, ready to drill.
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Using the template
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Finished piece
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