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Bob's RV-8 Build Site
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Date:  3-17-2021
Number of Hours:  2.90
Manual Reference:  
Brief Description:  Firewall Pass-thru

Tonight I tackled the Electrical Bay pass-thru. Stainless steel is kind of a pain to work with and it bit me a little once again tonight.

In my last log I had made a nice template to drill the hole pattern for the pass-thru. With the template located in place I drilled the center hole first and clecoed. I then began drilling the other holes and clecoed as I went. All this had to be done with my angle drill down at the bottom of the Electrical Bay. Room and visibility were limited which is why I used the template.

The problem is that using .032 aluminum for the template was a bad choice. I like to use mild steel as templates when I can because they are more solid but had none available to use. Well while drilling I didn't notice that the drill was actually walking just slightly ultimately resulting in three of the #40 holes to be off location by a little less than 1/16 of an inch. So I grabbed the Dremmel and using a small carbide burr I worked the holes back into location after marking the area to remove material to get the locations back in place. It worked well but took some time.

I then drilled out the large center hole with a 1.125 inch carbide hole saw I bought online. It really worked great and made a nice hole. Next I opened up the corner attachment holes.

Finally I deburred everything which with stainless is another pain but after working it for a while it was done. I screwed the pass-thru and the cover together and belt sanded a radius on the corners. Temp installed while waiting to get some attachment hardware in from ACS.
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Holes drilled with template

Holes drilled with template

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Radius corners of parts

Radius corners of parts

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Temp installed pass-thru

Temp installed pass-thru

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