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Dave's RV-7A Builder's Log
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Date:  10-26-2013
Number of Hours:  5.00
Manual Reference:  
Brief Description:  Side skirt fabrication

The process of fitting the side skirts includes fabricating and attaching a brace that runs the length of the canopy and serves to pull the bottom edge of the skirt in and hold it against the fuselage. This brace, C-791, arrives bent into an S-shape but must be trimmed to fit against the aft portion of the frame as well as curve to follow the shape of frame. To do this, the plans call for cutting 10 lightening holes along the length and cutting a notch at the bottom of each hole. This effectively turns a rigid piece of aluminum into a floppy mess. I was a bit skeptical that this brace would do the trick, but I’ve been surprised at how little aluminum it takes to make a very strong structure, so on we go.

First measure and drill the upper holes that attach the brace to the frame, and then out with a 1 ¼” hole saw to make the lightening holes. A couple of passes with the Scotchbrite wheel in the air grinder and then to the band saw to make the notches. Once the notches were cut and the edges worked with a file, I climbed into the cockpit and shut the canopy so that I could drill the brace to the frame. The drilling process is pretty straightforward—draw a centerline on the frame, line the first hole up and drill. Cleco that hole and start working aft until the aftmost hole is done. As I drilled I noticed that the skirt was often ¼” or more away from the lower portion of the brace and was a bit worried that I was going to have a pretty significant gap when it was all done.

The next phase of the fitting requires someone to sit in the cockpit and push the brace against the skirt while someone outside pushes the skirt against the fuselage and drills the two pieces (the holes in the skirt were pre-drilled). I had a fantastic surprise when I found out that Anna had come back home for the weekend and was willing to help. It didn’t take her long to get back in her building form and with her help we had the whole thing finished in a short time. Most amazing—the skirts are flush with the fuselage.
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Initial fitting on left side skirt brace

Initial fitting on left side skirt brace

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Anna helping drill the skirts

Anna helping drill the skirts

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Left side is drilled

Left side is drilled

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