I decided to install the optional external steps to make access easier to the cockpit with the nose gear configuration. The kit includes the installation instructions. Before I could start I had to remove the baggage side walls and floor from my quick build fusalage. This required drilling out some blind rivets and removing several screws. The fusalage already has a pilot hole which marks the location of the step tube that penetrates the fusalage. I decided to use a 1 1/2" hole saw that I already had. The instructions include a template that I made copies of for both sides of the fusalage. I taped the template to the fusalage to verify the step location. I used a slow speed and slowly drilled the hole through the skin. I deburred the hole and now I had to trim the F-623 corner rib flange so the tube would clear it. I marked both flanges of the rib where I needed to trim material. I used my small die grinder to remove material from both flanges. After a few trial and error fits the tube of the step slid smoothly in. With the template in place I was able to mark where I needed to drill the #40 holes for the several AN470 rivets that would need to be installed. I used the template to transfer the hole locations to the flange of the step. I drilled all the holes through the flange of the step while the step was secured in my bench vise. Now I needed to form the buttom of the step flange to match the contour of the fusalage. I used a heavy brass hammer and slowly formed the flange until I had a good fit. I installed the step and checked alignment. I used the holes in the flange as a guide to drill through the fusalage skin. I repeated the process for the other step.
