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Dave's RV-7A Builder's Log
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Date:  1-3-2009
Number of Hours:  2.50
Manual Reference:  
Brief Description:  Forward fuselage preparation

Since today's session involved cutting holes in skins, I decided to start by studying the plans carefully to ensure I didn't make a mistake. The plans have a template that I copied and transferred to a piece of stiff cardboard, and then cut out the hole. After tracing the cutout line on the skin, I used a hole saw to make the initial cut, then drilled out a couple of additional holes, and finally used a carbide cutter in my rotary tool to open up the hole. Aside from making a mess, it does a pretty good job of cutting away excess aluminum. After finishing the cut, I used a file to get the final edge--this involved a fair amount of trial fitting, but in the end, I was pleased with the outcome. Once I placed the F-772 skin back on the fuselage, I used the rotary tool and file to trim away the necesary part of F-704 to get the gear attach bracket to fit.

The next step was to position the F-713 longeron in place and drill it out. Like most parts that haven't been drilled, the plans call for marking a centerline and positioning the line so that it is centered in the holes in the F-770 skin. I drilled the aft section and then unsure whether I was to drill through the longeron and the firewall bracket, I decided to stop for more plans study and call it a night.
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Initial cut for gear attach

Initial cut for gear attach

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Hole in F-772 and F-704 for gear attach

Hole in F-772 and F-704 for gear attach

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F-713 partially drilled

F-713 partially drilled

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