Fitting, or match fitting the replacement rollbar is taking a tremendous amount of time. Details like the sequence of drilling holes, or multiple assemble/disassemble steps are required. Alignment must be checked against existing components and holes.
If a hole is enlarged or countersunk too soon it's more difficult to align and the brackets cannot be threaded if a match-drill in assemble is required later.
Managed to only drill one hole wrong and spent an hour re-fabricating the angle bracket. Finally happy with the fit and removed it all to clean-up, prime and re-assemble. Need to cut a 1.5" hole in aft F-631A both Lt & Rt sides. Need to add nutplates for the UMH guide blocks to close canopy straight, before closing up..
