Brief Description: Roll Bar - Flatten roll bar channel flanges.
In image 1, I’ve done something I haven’t seen others do. The flanges of the roll bar channels are not at all straight or flat. If you don’t flatten them then the distance between the top and bottom channels will vary greatly in distance apart and look bad. I used the vertically mounted belt sander to straighten out and flatten these flange edges. Didn’t need to take off much at all to get them flat and looking nice.
Image 2 shows the height of the roll bar in the jig. 17 19/32”. This matches the plans.
Image 3 shows the width of the roll bar in the jib. The plans cal out 42 5/32”. But I measured my fuselage and I need to add 1/32” to this. So my roll bar width is 42 6/32”, or 42 3/16”. The plans tell you it’s OK to adjust the width to match your fuselage.