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RV-7 Construction Log
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Date:  3-16-2014
Number of Hours:  7.00
Manual Reference:  p. 8-7
Brief Description:  Forward Fuselage

I started by finishing the drilling of the longerons forward of the F-706 bulkhead. I went as far as the F-704 on both sides, then took a close look at the fit of longerons to the skin forward of that point. At the F-704, the longerons have a radius instead of a sharp bend downward (impossible, IMHO), which causes it to run about 3/32 above the skin edge, tapering down to flush in about a foot. On the left side, I clamped the skin in place, marked the holes (photo 1), and determined that I have 1/4 inch edge distance, worst case. I don't have any idea what I'd do about it, so I'm going with it. The fit on the right side is practically identical.

After drilling both longerons all the way to the forward ends, I checked their lengths relative to the forward edge of the side skin. I had to trim the left one about 1/8", and the right one about 3/32" (photo 2) to get the forward ends at least 3/4" behind the skins. I then fabricated and drilled the F-704L bulkhead to longeron clips.

Lastly, I trial fit the firewall. It's just clamped in at this point, and I've done no drilling. I'm not sure about the fit of the engine mount bracket "fingers" to the inside of the longerons. The fit is pretty good at the forward end, but with the fingers being flat, and the longerons twisted, the fit at the rear is not so good (photo 3). I'm not sure whether to adjust the longerons or the fingers. I'll post a question on VAF before I proceed further.
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I don't think it's possible to get a sharp break at this bend in the longeron.

I don't think it's possible to get a sharp break at this bend in the longeron.

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Set up for trimming the right longeron.

Set up for trimming the right longeron.

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The fit of the upper left engine mount bracket to the longeron.

The fit of the upper left engine mount bracket to the longeron.

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