Started work on the nose gear today. The nose gear is composed of a long, welded steel tube (nose gear leg) with attach points for the rudder pedals and the shock cord (suspension) already welded on. At the bottom of the leg is a fork structure composed of two aluminum saddles: the fork which holds the wheel axle and a doubler which strengthens the fork.
I began by marking and drilling out the 6 bolt holes (and one drain hole) in the steel plate at the bottom of the nose gear leg which attaches to the wheel fork. I then clamped the strut to the fork doubler and used a transfer punch to mark the bolt holes onto the doubler.
I removed the strut and drilled out the 6 bolt holes in the doubler then clamped the doubler to the fork. I match drilled the 6 top side bolt holes into the fork and added two side bolt holes that attach the lower end of the droubler to the fork. Finally, I marked and drilled out the 3/4" hole for the axle on each side of the fork. After reassembly, voila! I have a nose gear strut...
... and a bunch more to do before it's on the airplane!
Nose gear: Axle, fork, doubler, and leg all bolted together.
Nose gear strut stuck through the upper bearing on the firewall for initial fitting.