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Kurt Haller RV-9A
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Date:  6-9-2012
Number of Hours:  8.00
Manual Reference:  8
Brief Description:  Tunnel cover fabrication, fit, and rivet.

Fabricated the tunnel cover assy (goes between the fwd flap motor channel that attaches to the seat pans and the slanted fwd seat covers. Lots of fitting the z-brackets etc. I decide to make the z-brackets align with the outer edges of the 0.040 Al sheet that forms the top of the cover, even though that made the holes on the bottom z-bracket flanges set too narrow to file the seat pan nut plates. Enlarge the holes from #19 to 1/4" and the cover fits in place nicely with little play. Will need to add washers to the #8-32 screws to better distribute the load and cover the gap that peeks out of one of the holes.

I went ahead and riveted the z-brackets to the top plate. Will prime the whole thing, then finish paint the outside. This part is "out of the weather" so the lack of prime on the faying surfaces isn't a big deal (until the day I spill a Big Gulp of Diet Coke in the cockpit, anyway....)

Pulled the parts for the fwd fuse bottom fuel line cover and cockpit heat diffuser and began to fit them up.
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Completed tunnel cover

Completed tunnel cover

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Underside...note enlarge holes on z-brackets

Underside...note enlarge holes on z-brackets

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In place (screws not torqued down)

In place (screws not torqued down)

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