Cutting the steps into the F-770 skins - 4 hours

Now the plans have you cut 1 1/2" diameter holes into the F-770 side skins for the optional step kit. Yes, I did choose to install the step kit. (P.S. I was relieved to see that Van's has reinforced the step kits as the earlier generation units had a tendency to crack at welds, at certain locations).

Next I really battled with did I want to cut these 1 1/2" holes now before the conical bend? I want to get that conical bend over with, however for the life of me, I just couldn't figure a way to cut the hole cleanly/easily after the skin was bent. Decision made....Ill cut first, bend later. Fingers crossed.

I drilled the pilot hole up to 1/4" then used a 1 1/2" hole saw on the drill (in reverse). Makes for a much cleaner cut and doesn't want to grab and mar the aluminum.

Seeing that I was going to work well...I de-vinyled before I continued drilling.


I managed to get both sides done and re-cleco'd the side skins back on.