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Date:  4-7-2012
Number of Hours:  5.00
Manual Reference:  
Brief Description:  Side job one almost finished

The next step in the plans is to rivet the F-724 and F-722 bulkheads to the side skin, This two bulkheads are part of the structure within the baggage compartment. The step after that would be to install the steps if you are installing them. I am not. but I had already started down that road before I decided to build an RV-7. I still had a hole on each side that needed to be plugged. I had already fabricated the backing pieces and they will be riveted to the F-724 bulkheads. So... I needed to finish this little project before riveting the bulkheads. The first step was to drill two plugs from 0.032 sheet to fit the holes. When riveted in place this will bring the material flush with the rest of the side skin.

Using a small scrap piece I drilled to 1.5 in plugs. They were a little large, but I did that on purpose. I wanted to custom fit each one. Then it was a slow process of sanding and filing to make sure they fit as close as possible. Then I drilled them to the backing material and dmipled both. I over dimpled slightly as I want the rivets to not to be visible when the aircraft is painted. Sounds simple, and it was, but it was also time consuming. They are already to rivet and when I start the fiberglass work I will us microballons to fill this area in. When its done you won't even know it is there.
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Step hole - earlier photo

Step hole - earlier photo

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After cutting plugs

After cutting plugs

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Ready to rivet

Ready to rivet

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