Worked on the F-772 bottom skin and F-796C&D spacers - 4 hours

I started the days build session by cleaning up the F-772 bottom skin. I feared that I was scratching the aluminum too much by taking the bottom skin on/off all the time. I broke all of the edges with a file, and then used a 3M wheel to smooth them out.



Next I used the edge forming tool and rolled the edge on the aft potion of the skin.


Next step that I wanted to do was to locate the hole on the upper tabs of the F-902 bulkhead to the longeron. They is virtually no room to work with here so before I did anything I marked minimum edge distance on the longeron.

On the tabs. I installed them temporarily, marked where the tab overhangs the longeron. and then started to mark minimum edge distance on all 4 sides.


I then drilled the #30 hole and confirmed proper edge distance. Next I Installed the bulkheads in the fuse and very carefully marked a pilot hole in the longeron with my 90deg drill set. I have just enough edge distance to work with. My drill set is too bulky to drill these holes, I will just need to finish drilling these when I take the longerons off to countersink them.
 
Next I turned my attention to the F-796C&D spacers. I had cut these out some time ago, but now I need to drill the top 3/32" hole. So I got creative.

Now when fitting the shims to the bulkhead, you will notice that you will need to make some adjustments.

Reading Mike Bullocks RV-7 build log, he notes that he had to trim about 1/16" off the bottom shim, and 1/32" off the top shim.. I'm going to do a bit more research on this.