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Larry Winger's 601XL Project
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Date: 3-15-2008
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Number of Hours: 5.75
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Manual Reference:
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Brief Description: Bottom access door installed
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Another day, another purchased part that needed to be re-made. The access door I was provided by Tom Henderson had an 8mm notch for the hinge, which is not in keeping with the latest revision which calls for 5mm. It threw the geometry of the part completely off, requiring me to make a new door. I didn't have any .025" aluminum, so I switched to .032" and actually prefer the feel of the part quite a lot. I had to reinstall my bending brake on the table (what fun) to make the criss-cross bends. I spent a couple of hours running for parts and making a swing by the hangar (to leave off my new Warp Drive prop). NOTE: While other nutplates are attached with solid rivets, this part requires blind A3 rivets. I have hundreds of A4s and A5s, but had never needed an A3. For the record, that has a body size of 3/32" which is the same as the small #40 drill (and silver cleco) commonly used to match parts before drilling up in size. Aircraft Spruce had no Avex A3s, so I went with Cherry rivets (CCP-32). By the way, these are protruding head (not countersunk) Cherry Rivets. That is because I knew I didn't have a modified nose piece to "dome" an A3 rivet...especially not one made of stainless steel. I just used an unmodified small nosepiece and they pulled just fine. I also spent an hour or so making a special tool for nutplate placement and drilling. I will describe the process in a separate entry for ease of reference. All-in-all, things came out great. My only addition may be one more nutplate on the leading edge corners, but that can wait.
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Looking aft
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The back edge
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Nutplates
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