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Dave's RV-7A Builder's Log
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Date:  7-13-2010
Number of Hours:  2.00
Manual Reference:  
Brief Description:  Fitting steps

This session was devoted to working on getting the steps installed. I first trimmed the end of each tube with a RotoZip (love that thing!) and then set about filing the opening in the fuselage skin to accomodate the weld. Turns out that the tube is 1 1/2 inches, and the hole that the plans call for is 1 1/2 inches, and that all works just fine until you realize that the welded joint adds about another 1/8 inch that must be filed away in order to allow the step flange to rest against the fuselage skin. After filing awhile I then put the flange in the vise and bent gently in a couple of directions to get the curve to match the skin. All in all it came out pretty good.

After doing that to both sides I measured and drilled the right side step. The plans called for a rivet pattern that just wasn't going to work for my setup, so I modified it slightly to ensure that I cleared all of the internal structure that shouldn't be drilled through. Next session will be the left step drilling, priming both steps, and fitting the steps to the internal ribs. Riveting the steps to the fuselage will be the last part and then on to fitting the baggage bulkheads.
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Right hand step after drilling

Right hand step after drilling

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Right hand step detail

Right hand step detail

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