August 16, 2015

Roll bar installation

Category: Forward Fuselage — Steffen @ 21:10 — Hours: 7.25

I’m a few updates behind, so here’s a post that covers the last two weeks.

According to my measurements, the roll bar brackets should sit about ⅛” behind the canopy decks. If I should redo this, I would have gone for 5/32“, but I’m not. 😉
Fuselage 649 [800x]

To hold them in place while matchdrilling, I used doublesided tape.
Fuselage 650 [800x]

Strangely, a lot of builders have problems with the brackets interfering with the edge of the seatback locks, but mine fitted perfectly! 😀
Fuselage 651 [800x]

As you can see in this picture, the brackets protrude of the side at the aft end. They have to be trimmed and shaped to follow the contour of the side skin.
Fuselage 652 [800x]

I matchdrilled the brackets to the fuselage frame.
Fuselage 653 [800x]

Having traced the trim shape to the brackets, I filed it into shape.
Fuselage 654 [800x]

Fuselage 656 [800x]

Fuselage 657 [800x]

Perfect, if I may say so!! 😉
Fuselage 655 [800x]

I marked and drilled pilot holes for the inboard roll bar bolts..
Fuselage 658 [800x]

Then drilled and bolted the bar to the brackets.
Fuselage 668 [800x]

With the bar securely bolted in place, I drilled the forward outboard bolt holes. (These are traced by the skin… look further down this post)
Fuselage 659 [800x]

I then drilled and countersank the aft holes. These will be hidden behind the skin.
Fuselage 660 [800x]

I then enlarged the skin holes and dimpled them for the forward screws.
Fuselage 661 [800x]

Forward holes countersunk, using the skin dimples as guide for the depth.
Fuselage 662 [800x]

Finally I tapped threads in these holes, hard to see, but they are..
Fuselage 663 [800x]

Tested. 😀
Fuselage 664 [800x]

That’s about it for the canopy frame. I still need to prime a few parts, but I will prepare some more parts before making another priming session.
So, I dug out some of the parts for instrument panel and subpanels:
Fuselage 665 [800x]

Did a quick test fitting before calling it a night.
Fuselage 667 [800x]

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