When I fitted the Roll Bar onto the cockpit rail I became aware of two problems:
1) The roll bar width was 1/8" to 3/16" too short and 2) The flanges were not flat enough to permit the vertical flange bolts from fitting [3/16" too high].
Although there is no measurement on the drawings I understand that the correct width of the cockpit at the WD-814 location should be 31 1/2", which mine is so I know that the roll bar is the problem and not my fuselage.
After searching the net for solutions, discussing it with my Inspector and Van's I borrowed a handle winch and some strops from Adrian at work and stretched the roll bar between our apple and pear tree!
This worked great and to gain my extra 3/16" I stretched the bar 1 1/2" before it sprung back to the required width. The center of the upper longeron fits perfectly in the centre of the lateral bolt holes in the flange but the stretch did not lower the inboard section of the flange
