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Wendells RV-6A
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Date:  3-12-2012
Number of Hours:  6.00
Manual Reference:  Roll Bar
Brief Description:  Drill Joint Strips into Forward Roll Bar Half

And I thought I had a lot of clamps. I ended up using everything I could find to squeeze those joint straps tight and all the way down as far as they can get before match drilling them. I used the scothbrite wheel to curve the inner edges of both joint straps to help keep them flush to the roll bar flange down low. Lots of clamps necessary to squeeae it very tight. Marked a mid line on the straps and positioned that line in the junction of the two halves. Went all the way one direction and then started in the middle the other direction. Did the longer strap first( the upper one) followed by the lower, shorter one. Next step will be to remove all those clamps, position the aft roll bar halves at the proper overall width of 1 1/2 inches and then match drill the aft roll bar halves to the joint straps. I will place some 1 3/8 inch wide spacers inside the roll bar to maintain the overall 1.5 inch size. Then onto those slanted angles at the base and I can test fit it. More parts for the priming box.
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Tap on the joint strap with the wood block and hammer to keep it bottomed while you tighten clamps up.

Tap on the joint strap with the wood block and hammer to keep it bottomed while you tighten clamps up.

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Any old clamp in a storm....

Any old clamp in a storm....

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