Brief Description: Cut and drilled roll bar spacers.
The roll bar is bolted to the forward part of the aft canopy decks. The holes are measured to the 1/32" tolerance so as to nestle the bolts against the top longeron. I drilled the pilot holes that will eventually be drilled to final size (3/16" and 1/4") through the roll bar flange and aft canopy deck. Spacers need to be cut and drilled to fit below the canopy deck and against the bottom of the longeron flange to hold the roll bar in place. Cutting and drilling the spacers was tedious because I needed two sets of reading glasses to see the 1/32" and 1/64" marks on the steel scale. I cut the spacers with the band saw, much like measuring with a micrometer and cutting with an axe.
Marking the holes to be drilled on these tiny spacers required a centerline marking and then inserting them below and beneath the canopy deck which I could not do with my hands and fat fingers. I used some small vise grips to hold the spacer and slid it back and forth along the longeron inside the canopy deck curled flange looking for the centerline mark through the pilot holes. Now, give me a break! Working in the blind at 1/32 to 1/64" tolerance. Well, I finally marked the spacers through the pilot holes with the #40 drill bit. I used the drill press to pilot drill the spacers and then final drilled to the approriate size holes. I can't tell if they are drilled right or not. If not then final drilling the canopy decks to final size may drill into the longeron and that is a no-no. I've had it for this day!
Spacers cut to dimensions per the drawing.
Drilling the spacers with drill press.
The top right spacer appears to be drilled to close to the longeron.
