Decided that I had to spend some 'airplane time' after days of crisis management at work. Bad Idea.
After inserting the rear window and securing the skin edges with clecoes, I carefully mis-marked all the positions for drilling the rollbar holes through the plexi. The rollbar had been covered with blue painters' tape for months with the EXISTING rivet positions marked on the tape. I was supposed to remember to mark the plexi BETWEEN the rivet marks but didn't --- which resulted in drilling out a major portoin of the pulled rivets in the aft F-631's, especially on the left side. (see pics)
The only logical repair is to drill-out all the rivets and replace the F-631A L&R (bows) to allow the re-postioning of the rivets between the plexi holes. If I try to enlarge the holes to rivet the plexi now, the existing blind rivets with either fall out, or distort the plexi rivets making for a difficult repair near an expensive window. (Adding rollbar rivets alone will not solve the alignment.)
A GOOD NOTE taped to the rollbar would have reminded me of the PLAN and meaning of the marks. ($135 for new parts and probably 8 hrs of work.)
