Now that the F-782D angles are drilled to the web attach gear, we can position and drill the #19 holes for AN515-8R8 screws on the outsides of the F-782A cover plates.
The difficulty here is making sure that you have edge distance on both the angle and the cover. I drew a line at minimum edge distance on the angle and drilled pilot holes in the cover.
Next is making sure that the ground angles don't scuff against the opening on the cover plate. I had to file a bit away on all of them to have the angles cleared.
Don't forget to drill the #19 hole on top of the cover plate where the foward seat pans connect with the cover plate.
I had some time left and decided to cut the fuel line passthrough hole in the F-782C center cabin cover.
I'm using an andair fuel pump and the plans nicely indicate for an RV-7 where to cut the hole. The aux fuel pump will sit right behind the fuel selector cover and is screwed on top of the center cabin cover. On the exit point, the fuel lines bend down and continue underneath the center cabin cover.
I measured carefully and drew centerpoints for the circles that will define the radiuses in the corners.
Drilled the holes with a unibit to size.
After some cutting, filing, edge deburring and sanding, the center cabin cover cut-out is ready.
I got some help today from my step father. He came by and started making some small angle pieces which I will need later for the top forward skins.
Center cabin cover temporarily installed.
Then I started making the stick booth covers. These are some funky think rings which will hold the stick booths in place in the forward seat pans between the pilot and passengers legs.
It's a bit of a waste as you need a full size sheet of stock material and more than half of it will be cut away.
The plans don't really say how you should do this so I made quite a bit of pictures to illustrate the process.
First cut out the full size sheet. I actually even made them oversize to start with. That way, if my bent is not perfect, I can stay play with it.
Then I took out the bending brake and bent the sheet according to the dimensions specified in the plans. Pretty easy so far.
Then, I clamped the sheet down on the seat pan with the bend line aligned and checked if the holes around the stick booth fit well on my aluminum sheet.
They were in the right locations with plenty of edge distance at this point and so I drill the 6 holes to #19 to receive AN515-8R8 screws.
Then I took a sharpie pen and outlined the inner countour on my sheet.
After removing, this is how it looks like. This defines exactly where I need my cutout for the stick booth ring to align perfectly with the seat pan.
Same process as usual to defined circle centerpoints and make radius cuts with a unibit.
Rough cut on the parts and start filing away with the vixen the rest of the material. Then gently work your way to the line and deburr and sand the result.
Finally, I started meauring the outside perimeter distances from the holes and grinded the excess material away on the scotchbrite wheel. Rounding the corners and you're done.
And there's two of them so you repeat the process on the other seat pan. They are not identical so make one at a time.
