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Greg's RV-9A Builder Site
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Date: 12-6-2007
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Number of Hours: 5.50
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Manual Reference:
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Brief Description: Steps, Baggage Bulkheads
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Finished fitting the steps. First, I repeated what I did last, on the right side, by measuring out the holes, drilling the holes, and then placeing the formed step base against the skin and match drilling. After both sides were match drilled, I drilled the bushing blocks in the drill press. I messed one hole up in the corner, so I just rotated the block and used another corner. Then I put the step back on, clamping the block to the rib, and drilled the shorter bolt holes using the angle drill. Then I used a pilot bit in the angle drill to mark where I need to drill the step tube, removed the step and drilled those holes in the tube. Finally, I cleaned up the edges, rounded the corners, and countersunk the holes for the rivets. Again, the top three aft holes in the step will get reinforced from the back side by a 1 inch strip of 3/8th inch aluminum. After I prime them, I'll install them for good. Then I cleaned up the baggage floors, deburred the edges and holes, installed the aft baggage side covers, and the floors and finally the corrugated baggage bulkheads. The bottom one was easy, with holes predrilled in the bottom. The top one had to be radiused to fit the bulkhead, and then put in place. I used tape to hold it in place after I measured the vertical placement. Horizontal placement was easy, just line up with the bottom part. After getting it all straight, I drilled #40 holes and cleco'd in place. I'll match drill to final size next time. Before installing the top half, I made the notches for the seatbelt anchors. At the end of my working day, I finally sat in the plane for the first time. No airplane noises were made, I just said "wow, this is cool." I think it's going to be a great fit.
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Step holes in right side
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Holes drilled and countersunk
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Baggage Bulkheads in place
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