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Jims RV-8
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Date: 8-21-2014
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Number of Hours: 2.90
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Manual Reference: 8-16
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Brief Description: Forward Fuse – Drilling Left Lower Longeron
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So tonight I was able to get Left Lower longeron (F-843-L-1) drilled! It took a bit of time as it was not a difficult process, just time consuming. To start, the plans have you move the whole Forward Fuselage Sub structure so that the left side overhangs the workbench. This is because the lower longeron slides above the bottom skin – where the holes are, that you use to match drill the longeron. So, the holes get drilled from the bottom up. Since I would be drilling upside down and at different angles, I decided to use my drill cup. The drill cup helps to align/hold the drill perpendicular so that you get a nice drilled hole.
Like I said, not difficult, just time consuming… Per the plans, I drilled the aft most hole first and clecoed that one. Then, I drilled the 4 forward holes that go thru the lower longeron and the lower engine mount. The 4 forward holes are drilled to #30 first, and then final drilled to #12 to accept the bolt. The bolts are temporarily installed in the front and rear (2 of the 4) holes to hold the alignment. Then basically the rest of the holes get drilled (upside down) to #30 and the two holes that hold the skin, the lower longeron and the WD-822-L-1 L.G. Box Weldment get final drilled to #19 and then countersunk to be flush and out of the way of the landing gear. So you can see everytime I go from #30 to #12 back to #30, then #19 it’s a switch of the drill cup and the drill bit.
With the drilling done, I unclecoed and unbolted the whole thing and pulled out the lower longeron to deburr all the holes that were drilled in the previous steps. Then the aft end of the vertex of the lower longeron gets radiused (for a yet-to-be-determined reason) and the longeron goes back into the Forward fuse structure and gets clecoed and bolted back in to hold the structure while I do the other side. That’s all for today…
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left side done, right side fit
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drill cup with various size fittings
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