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Buck's RV-8
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Date: 4-8-2009
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Number of Hours: 2.20
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Manual Reference:
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Brief Description: Forward fuselage skin
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Today I got the forward skin drilled and clecoed to the instrument panel flange. In order to prevent the skin from being slightly buckled down near the bottom edge where the instrument panel flange has a gap, I began by removing a half-dozen of the clecoes on the outboard bottom edges of the instrument sub-panel, and then pushed the flange up to meet the skin. I marked the new position of the flange and removed the skin and panels. Then I re-drilled the flange to its new position along the sub-panel. (Since I enlarged the holes to #30 to do this, I'll use "Oops" rivets to fill the larger holes.)
Then I reinstalled everything and drilled the skin on. The process worked pretty well. There was only a small gap remaining. My friend Jim helped with drilling and clecoing. I plan to cover the gap on the inside of the cockpit (along the outer edges of the sub-panel, where the backside of the flange now shows a bit) with engraved panel plates that will contain the switch markings.
My only bummer of the day came when I saw that somehow, I've developed a small mismatch in the overhang of the skin on the fuselage. The left edge is higher by about 3/32". I hope this doesn't cause any issues when drilling the skin through the longerons. It certainly won't be noticable unless someone actually measures it. I'll think about this issue over the next few days.
Finally, I installed the avionics access door and clamped the baggage compartment hinge channel in place, then marked where I will have to notch the avionics access door for it to clear. Also, I noted that the hinge channel, built to plans, is about 1/8" to 3/16" too short, so it will require a shim.
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The baggage door hinge channel (top) will require me to put a notch in the avionics access door.
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I had to do a little trimming of the skin along the edges so they didn't rub on the rollover bar.
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Skin drilled and clecoed to the instrument panel.
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