I received answers back from Van’s on my issue with the aft bulkhead. Ken Scott said this is typical and make a shim for the area is the correct course of action. I also received a reply on my canopy bow; Ken also answered this one as well. The welds are plenty strong and in the areas with the bows on can use shims if wanted. He suggested some proseal to keep the shim in place since there are no fastener in this area.
So armed with this knowledge I made the shims for the aft bulkhead and then match drilled the holes to #40. I then took a deep breath and drilled all of the holes holding the canopy bow in place, and I must say I am please with the results, no edge distance issues. The forward part sits nice and flush with the rail but the aft hole has a bit of a gap, I am sure it will tighten down, but I made a shim for the aft side anyways. With that stressful task behind me I took the aft skin off and match drilled the lower holes common between the lower shin and the upper longerons. I was going to dive into drilling the F-807 gussets but it was already late and I had to feed the horses since Anita is out of town today. I am really getting excited about flying this thing next year; I sure hope my goal is realistic, oh well just one day at a time.
Stop nut will be used in final assemply, I use castle nut for temporay installs
Bottom side.
Now I have to remove the thing and deburr all of the holes!
