Brief Description: Roll bar assembly and fit prep (24-02)
I started the day machining the countersinks into the outer flange. It's challenging to set-up the micro cage just right since some areas are on the curve and some on in the flat. I decided to leave everything clecoed in place except for the hole I was countersinking. This gave me a little more surface area to push the cage against. I basically ended up leaving the tool sticking out a little too far ouit of the micro cage, then I just machined a little of the counter sink at a time, then trial fit in the CS-4 rivet, then machine a little deeper until it was the right depth. It took a little while. I then went back to deburr all the holes and primed the parts that don't show...inside of the roll bar, the straps and splice plates. I also added the slight bend to the canopy latch per the instruction. I'm still not finished, but I think I will try to fit the roll bar on the braces before I rivet everything. There were a couple spots on the roll bar where the hole punch raised the metal around the hole and the outer flange has a stop sign bumpiness, so I wrapped some sandpaper around a block and tried to smooth it out a little. I’ll probably need to do some more smoothing prior to interior painting.
Roll bar base temporarely bolted into place
Canopy latch deburred and added bend
Machined counter sinks and sanded flange to smooth out the bumps a little
