A flashlight peek under the skin made me worried about the edge clearance on HS-702 flange for the skin rivets. So, I ordered new HS-702, 404 and 405s from Vans. Got home and pulled the skin so I could really check and … lo and behold … the holes are just in the right place! Reclecoed the skin and finished match drilling the left skin and the HS-710, 714 brackets. Marked where 404 and 405 will need some edge shaving to become flush with the skin. Just a few mils, easily done on the belt sander. Received the CherryMax size 6 pop rivets ... will work great for the earlier oops.
Assembled the skeleton for the right side. This time, I stripped the plastic off and drew a rivet locaiton line down the edge of the 702 flange on both sides. Clecoed on the skin and marked the positon of the intersection of the 702 flange and the skin that made the rivet line show up in the prepunched holes. Dry fitted the HS-404 and it looks like it will properly positon the 702 exit from under the skin once installed. Marked the hole positons on 404 and 405 and will flute tomorrow. Note: always physically assemble and mark all cut and trim points prior to cutting.
Don't rely on the plans dimensions and open-loop cut ... this would have improved the fit of the 702 trimming to the edge of the skins and the 404, 405 fit around 701 and 714. Always mark a rivet line on clean bare metal and ensure alignment before drilling.
