I have seen on other builder's logs where they have modified the arm rest. It is just a piece of thin bent alum. and if someone used it to lift themselves in or out of the plane, it might bend or kink. I used a piece of 3/4 light weight angle to strengthen this. I measured the length, cut and then rounded the apex corner so it will fit snuggly in the bend of the arm rest. I then decided to drill holes every 2 inched on the sides and every 4 inched on the top. this should work and will not add much weight. I'm pretty much to the point where everything is complete and I am ready to prep and prime. I went to NAPA auto parts today and picked up another 6 cans of Self-Etching Primer. I also want to think about how I plan to paint the interior....
The angle sticks out about 3/16 of an inch. This will be trimmed on the band saw
I also rounded the apex of the angle to fit better. The left one is rounded, the right one is not...
After trimming, drilling, deburring, countersinking and dimpling, the parts fit together perfectly!
