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Buck's RV-8
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Date: 10-24-2007
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Number of Hours: 4.80
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Manual Reference:
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Brief Description: Pedal access hatch
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Today, I finished drilling the screw holes in the cover plate and attachment ring to #19 size, then drilled the ring for the platenuts. Next, I countersunk all the #30 holes in the attachment ring.
Then, it was time to make the big cut -- the hole in the fuselage. I simply laid on the floor next to the fuselage with a Dremel tool and trimmed close to the lines. As always, it feels odd to hack a big hole in a nice, perfect skin. Once I'd cut a rough hole, I used a notching tool, a 2" drum-sander, and various files and sandpaper to finish off the edges of the hole.
I dimpled the cover plate and attachment ring, and as I expected, they both curled quite significantly in the process. I spent about 30 minutes flattening them by hand. (I've found this to be the best way to do this. There is no tool or process I know of that allows the required level of finesse). I clecoed the attachment ring to the fuselage skin and fine-tuned the fit of the cover plate. It looks really good!
Finally, I primed the attachment ring, the inside of the fuselage skin along the line of rivet holes, and the inside of the cover plate.
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Hey, somebody hacked a big, ragged hole in the side of my fuselage!
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Four hours later. It looks much better now.
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