Brief Description: F-705 BH - Clamp BH in prep for drilling 705G's.
First you cut the 705 G angles to final length from AA (aluminum angle) stock. The plans can out a length of 2 9/16". Well I left mine about 1/64" over length to help assure I don't violate the minimum edge distance when drilled. Looks like I could have left them even long without any problems.
The 2" side flange of the 705G gets reduced to 1 3/4". But don't do it yet. Do it after it's drilled. Also the 705G gets a taper cut on one side to alaign to the bulkhead. Again, don't make this cut yet. Wait untill the 705G is drilled. You'll get better alaignment if you wait.
Now the tricky part. This 705G angle fits in the corner of the bulkhead. We will match drill the angle using the holes in the bulkhead as a drill guide. The problem is that all the holes we will drill through the angle are holes that need to used to cleco the two halves of the bulkhead together. So, the probelm. How do get the two halves of the buckhead and angle ligned up and clamped for drilling. You can cleco the bulkhead to alaign it but then have to remove the clecos to position and clamp the 705G angle. What the heck.
Here's what I did. 1.) Put double sided tape between the mating surfaces of the two bulk head parts, as in Imgae 1, and cleco them together. 2.) Using scrap wood, clamp the two bulkhead pieces together. I used two cross angles for this. 3.) Remove the clecos, position and clamp the 705G. The clamped cross members keep the bulkhead in perfect alaignment when the clecoes are removed. 4.) Drill both sides of the angle.
Double sided tape helps keep things in proper position.
