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Justin Shumaker's Kitlog
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Date: 2-19-2013
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Number of Hours: 7.00
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Manual Reference:
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Brief Description: Firewall Drilling and Cleco'ing
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I would have liked to upload about 6 pictures, so I will do some explaining. I started with F-650 and the F-138T gusset plates. Lots of drilling and cleco'ing. These areas are very tight, so the use of an air drill and a long 12" drill bit will help out here. Furthermore, with some of these parts that have the 3/32 predrilled holes, it some times is easier to drill the two or three holes that you can actually get to from the top then cleco the gusset plate to the bottom side, and remove those parts from the cabin and drill those holes on a workbench. This eliminates the need for a special right angle drill and so forth. There's always a way to make things easy, you just need to be clever and do things in the right order.
The bottom gusset plates F-138B and F-637 require shims. I noticed this on Ian Swinborne's log as well. He indicated 2mm shims, but I used 1/8" shims since that is the thickness of the "L" channel. Furthermore, the cabin is 1088mm while the front end of the firewall is 1069mm, so you have to really do a good job and square everything up, very time consuming. Afterwards you will need to squeeze the front end in a little bit since you are going from 1088mm to 1069mm, about 9mm or 3/8 on each size. Make sure you have some strong screw clamps to hold everything in place while you get those first few cleco's.
All in all, everything is symmetric, square and level.
Update: The next log shows these shims are actually incorrect and that PF-138B should be on the outside not the inside of the frame.
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Clearly a shim is needed
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Shim installed
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End of another days work
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