TitleGarrison

No bird ever flew nonstop from New York to Tokyo, or raced 15 miles high at triple the speed of sound.                                                                                                   
  But birds do something else.
  They do not conquer the air; they romance it.
.”

  Peter Garrison

HoursAndCounting

Jur's RV7 Aircraft Factory
2917 hours
and counting
Some decisions in life are bare of any obvious logic

 

Here's one of these things that's not explicitely mentioned in the manual or on the plans but that should not be forgotten.

The F-7101 gear attach doublers are installed on both the RV7 and RV7-A version. On DWG28, there is an instruction to enlarge a pilot hole to 1inch for the fuel line pass through rubber grommet.

Since the F-7101 butts at the same location on the inside, the pilot hole there also needs to be cut to 1 inch as the fuel line will also need to penetrate the side of the aircraft at that point.

Some caution here. I read on many sites that some builders just cut the 1 inch hole on the F-7101 using a 1 inch cutter and go with that. They found out that there are alignment problems if you do that.

There for (and also because I don't have a 1inch cutter I admit), I decided to follow another methode which is a bit more "crafts work" but gives excellent result.

It started bu cutting with the largest cutter in my rotacut set which is still way undersize of 1 inch just using the pilot hole.

I then removed all my auxilliary longerons and the bottom longeron from the side skin and peeled back the side skin.

The reason I did this is because I want to line up and mark with a sharpie pen the already existing enlarged hole in the side skin with the F-7101 "to be" cut.
Since the F-7101 normally sits on top of the longerons, that would not be possible. I wan't both skins to butt to eachother in order to make a nice copy-drawing.

In the picture below, you see that the F-7101 can easily be clecoed to the side skin if you pull it away.

So now this is the view from the outside. I can easily transfer the hole of the side skin on the F-7101 remaining surface.

Once that is done, I used a dremel tool to cut off the major parts and finished it off by hand with a small rounded key file regularily measuring with a caliper for 1".

Fitted it in place again "et voila" a nice match.

View from the inside.

Did the same trick then on the left side and got a similar good result.

 

One thing that I didn't found immediatly is the question if the rubber grommet is put over both holes at once, or if there is only a rubber grommet in the first and the second hole is left open, of if both holes take a rubber grommet.

I checked out some builder sites and it seems that both holes take a rubber grommet. That will be fun to install once I make the fuel lines as it looks like a very thight fit.

Another option I discovered is on Dan Checkoway's site. He has cut out some lightning holes from the F-7101's. After all, we are not building an RV7-A and these parts don't look like being structural for an RV-7 and this is beefy 063 material.

Couple of ounces here and there... Still thinking about it and will decide .

The more I look at the reassembled place, the more stuff I found that I still need to do before priming. Discovered that I still have not deburred and dimpeled the bagagge compartment bulkhead and covers.
Also found out I forgot to countersink the forward #30 holes that attach to the steel brackets. At least I know now why the fit of the side skin to the longerons looked so horrible :)

How to use

Use the kit buttons in the top ribbon bar to see a chronological overview per sub section per kit. For the full chronological article list, see chronological build link in prelude menu here below. The easiest way to lookup information is by typing in some part numbers or keywords using the search option in the ribbon bar

 

Caution !

Some advice on reading my log for fellow builders !

In some articles, I made corrections at later date on the original article to rectify my own stupidities or faults. Read through the entire article if you intend to use my findings/experiences on your own project !

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It’s possible (not likely) that I’m not as smart as I think I am. (Occasionally, I have moments when I know this to be true. Fortunately, the feeling passes quickly.) Although I have tried to make this information as accurate as I can, it is not only possible, but also quite likely, that erroneous and misguided information lurks within these pages. I cannot and do not warrant these pages to be error free and correct. Furthermore, I accept no liability for the use of this (mis)information. And, as many would say, your mileage may vary. If, after reading this, you are intent on proceeding, please be aware that the contents of this site are protected by copyright (copyright © 2011 and 2012). Nonetheless, you may copy this material subject to these two conditions: (1) any information used is for non-commercial purposes, and (2) the source of the material is properly credited. Of course, you may link to any page herein. At some articles, snippets of the plans from Vans are visible. These are for educational and illustrations purposes only and should never be used as plans for part construction or assembly as plans may have changed since the picture was taken and more important they are protected by Copyright by the Vans Aircraft Mothership company.

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