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CON'S WEB SITE
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Date: 11-25-2013
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Number of Hours: 9.50
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Manual Reference:
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Brief Description: Notched Longerons, Installed ELT and Strobe Mounts
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5 hours of progress and 4.5 hours of "redo."
I tried to clamp a piece of .032 to the right longeron and then drill the aft canopy deck to the longeron. The deck walked a small bit on the first hole and so it sticks out slightly greater than .032. I may have to sand it to the proper dimension further down the road. Time will tell. On the left canopy deck, I followed the directions and taped the spacer to the longeron. This deck came out spot on. I removed the decks and used the aft deck to mark the notches in the longerons that I need to cut. I drilled a hole in each longeron to achieve the proper radius and used a hacksaw, Dremel tool and file to finish the notches. I then clecoed the longerons into place. I was hoping to have Ginger assist me in joining the center and aft fuselage assemblies when she got home later. Miles Bowen (another RV-7 builder) emailed me about the Orndorff method and I was hoping to know exactly how my longeron bends came out before I replied.
While waiting for Ginger, I installed the platenuts on the ELT and Strobe Powerpack mounts. I then riveted them onto the J-Stringers using pulled rivets. As you can see in the pictures, I riveted the bottoms first by pulling the plate away from the skin to allow access. Once the bottoms were riveted, I pushed the top of the plate back into position and riveted those four holes.
When Ginger came home, I discovered that I had riveted the F-779 between the F-778 and F-773 skins instead of under the F-778. I ignored several clues that I had screwed up: (1) Primer was showing on the overlap portion of the F-779, (2) the F-773 skins kicked up where they intersected the F-779, (3) the W-409 no longer fit perfectly flush against the F-712 bulkhead, and (4) the tailwheel mount now slightly rubbed on the "mouse hole." 4.5 hours later, I had drilled out all of the rivets attaching the F-779 and F-710 bulhead and had them clecoed back in the proper order. Most holes were fine, but I will need to use a few "oops rivets."
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Drilled Aft Deck to Longerons
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Installing ELT Mount to J-Stringners
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ELT Mount Installed
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