The photos are a little out chronological sequence but the task started with a layout on the bench of the F-631 Lt & Rt pieces according to the actual measurements of the fuselage. The width of the F-631 must be adjusted if the fuselage differs from plan, overall of 42 1/2" minus the 3/16" on each side for the F-631 outbd angle brackets. This fuselage was spot-on across the longerons at the front edge of the seat back support.
The aft components of the 'rollbar' were trimmed slightly (filed) on the bottom portion of the Lt & Rt joint to allow the ends to 'close' in to the specified 42 1/8" to the outsides. The F-631E reinforcement plate was layed out for drilling to #40 and backdrilled in just a few of the holes to cleco the Lt & Rt sides together. The top row was NOT drilled at this time to allow that to be done 'in assembly' with the support for the F-632 components (top angle).
After assembly of the Rt & Lt sides, the F-631A strip was trimmed along the inside edges to allow a firm 'seating' along the inside curvature. Each strip was then clamped into the Rt/Lt channel and drilled at 1 1/4" spacing along the entire inside and outside channels, clecoing in every hole, and cleaning out debris to ensure the strip was 'seating' tightly as it progressed. (#2 shows tight fit of strips).
Preliminary completion of the aft components. Deburred and cleaned up for now. Attached Rt & Lt components and plate (F-631E) of the fwd components, test fit and set aside.
