Used the same 5 drill bit process to enlarge the four 3/16 holes in each weldment, wing spar and mating holes in the F604 to accept the AN4 bolts, ending with the .249 reamer. Finished enlarging all the remaining #30 holes in the weldment to 3/16, matching the wing spar holes. The worst part of the whole process was a hole in each weldment too close to a weld for AN4 nuts/washers. I had to grind down the weld and open up that side clearance so a AN4 washer and nut could fit. You cannot turn the nut. One flat side of the nut rests very close to a welded side plate on the gear weldment. Same issue on both weldments. They will tighten up ok using a socket on the bolt head. There were also 3 AN3 size holes that were too close to a welded flange. On one I made a small mouse hole and used the appropriate back spotface cutter to give me a perfect flat surface for the AN3 nut/washers. The other 2 AN3 issues just required back spotfacing away a corner edge of interfering flange. Love having the right tools. Also hate have poorly manufactured gear weldments. There was no call to have such a close clearance issue if a little better quality control existed. I see several websites that had the same issues on the RV-6A. It would have been really cool if Vans had predrilled the weldments like the newer models... Had the opportunity to use my angle drill extension to get to the lower holes in the F604 main spar bulkhead. It is always a pleasure to have the right tool. The weldments are 100% finished. Hurraaah!!. Pictures soon.
