Today I attempted to fit the F-6101 gusset to the lower longeron and crossmember. Once again, The Vans supplied F-6101 seems unsatisfactory. In older kits, this piece is supplied as rectangular stock with one edge pre-formed to a 90 degree bend. On later kits like mine, the gusses is pre-cut so it should fit in the angle formed by the lower longeron and the other crossmember that attaches to the lower weldment. Since the pre-cut part did not fit correctly I became concerned that I had something jigged incorrectly. I spent the rest of my building time for the day rechecking every measurement. Everything check out ok, so the problem is not the assembly.
I called Vans on Thursday morning to find out if there is something I am doing wrong. The support person said they hadn't heard of any issues with this part, but there aren't that many RV-6 kits out there using this newer part. He asked that I send a picture with dimensions so they can verufy that it is not a manufacturing defect. There are no drawings specific to this fabbed part in the plans.
In the picture below I show the F-6101 on the outside of the longeron, this is just to demonsrate the mis-fit. The F-6101 attaches to the inside of the longeron and crossmember.
