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RV-7 Construction Log
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Date:  4-6-2014
Number of Hours:  9.35
Manual Reference:  p. 8-8
Brief Description:  Forward Fuselage

I started by fabricating the right side angle clip that attaches the forward skin stiffener to the firewall vertical stiffener. This being the fourth one I've made, it only took about 20 minutes. I then pre-drilled the three holes in each clip called out on dwg 23. I lamped the left clip in place and adjusted the height of the left stiffener for drilling. I then braced the left skin stiffener to maintain its proper position and peeled the skin back (photo 1) for drilling the clip to both stiffeners. See results in photo 2. Note that I notched the forward inboard corner of the stiffener to clear the vertical firewall stiffener.

I then fabricated both F-717 lower longerons, including trimming the aft 4-1/8" off of the horizontal legs, and adding the twist. I had to shorten both of them about 3/32 to 1/8" compared to the plans length to get them to fit flush to the vertical bulkhead member. Also, the aft end fit best when trimmed square, rather than the 1/32" angle over the width of the leg called for on the plan.

I then laid out and pre-drilled to #40 the four vertical bolt hole locations in the forward end of both lower longerons. I then removed the bottom skin and test fit both lower longerons. With the forward ends clamped firmly to the lower engine mount brackets (photo 3), the lower longeron does indeed extend 1/8" below the bottom of the F-770 side skin along its entire length, as it should. I drilled the vertical bolt holes in the left lower longeron to the left lower engine mount, progressing through #40, #30, 11/64” drills, followed by a 3/16" reamer.
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The forward skin stiffener braced so the skin can be peeled back.

The forward skin stiffener braced so the skin can be peeled back.

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The angle clip drilled to the skin and firewall stiffeners.

The angle clip drilled to the skin and firewall stiffeners.

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Lower longeron clamped in place ready to drill the vertical bolt holes.

Lower longeron clamped in place ready to drill the vertical bolt holes.

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