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KENNETH T.'S WEB SITE
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Date: 5-4-2009
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Number of Hours: 7.00
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Manual Reference: Dwg 42
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Brief Description: Finished installing the roll bar.
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Today, I decided to finish installing the roll bar. My worry was that the spacers were not quite drilled right and that when I final drilled the canopy decks I would drill into the longerons. After a lot of reviewing the drawings I realized that I could grind off the inside edge of the spacer just a bit to insure that the bolt would just rest against the longeron. I then drilled the canopy deck pilot holes to final size after slightly elongating the right front hole toward the center of the fuselage about another 1/32". They all came out perfect, by that I mean that I did not drill into the longerons at all.
I had clamped the roll bar onto the decks and marked the flanges by hand from beneath using the #40 drill before drilling the deck to final size. I final drilled the roll bar flanges (on the work bench) to final size (forward bolt 3/16" #12, aft bolt 1/4"). My brother, Clark, called and I asked him to come over and help me bolt on the roll bar. I then scuffed and primed the spacers. When my brother arrived we attempted to bolt on the roll bar. Not being able to use ones hands on the aft bolts, washers, and nuts we tried many different ways using many different tools trying to get the aft spacers, washers, and nuts up under the lower flange of the canopy deck. Finally, we had an epiphany and super glued the washer, then nut to the spacer. We just slid the spacer to the hole as seen from above and inserted the bolt and torqued the whole mess together. It only took us three hours of fumbling and dropping tools and parts before we had the vision. Lesson learned, think about it before saying, "I can do that, no sweat."
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Photo from the spar up to the lower side of deck with spacer, washer, and nut bolted to roll bar.
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The roll bar flange bolted to the aft canopy deck.
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Roll bar installed.
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