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RV-7 Construction Log
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Date:  4-13-2014
Number of Hours:  8.65
Manual Reference:  p. 8-9
Brief Description:  Forward Fuselage

I started today by drilling the attaching parts for the right tank bracket to the fuselage. It went fairly quickly after spending a substantial part of the day yesterday learning how to do the left one...

I then finished match drilling the auxiliary and lower longerons on both sides, including the gear attach webs, and the lower longeron holes through the lower engine mount brackets.

I then broke out the parts for the rudder and brake pedals. At first I thought I was short two brake pedals, and then discovered in my inventory sheet that the "dual brake kit", including the copilot pedals, is in a separate bag, which I found on my shelf. I deleted the brake master cylinders from the fuselage kit because I want to go with Grove rather than Matco, but I had no idea I'd need master cylinders this early in the build. I'll get the Groves on order soon.

I started by fabricating the 8 required F-6117C brake pedal support angles, then deburred (belt sander) and polished (scotchbrite wheel) the edges of the four brake pedals and side plates. I drilled support angles (photo 1) and the side plate to one pedal, then decided to get started on locating the rudder pedal bearing blocks in the fuselage. I figured drilling the rest of the brake pedal parts will make good short-term projects after work this week.

I noticed on drawing 37 that the holes in the bearing blocks for the rudder pedal bars are drilled at a slight angle. This isn't obvious to the naked eye, but a quick measurement with the depth gauge on my caliper revealed that one side of each hole is slightly deeper than the other side of the same hole. Considering the angle of the fuselage sides, the deeper sides of the holes go forward.

Photo 2 shows how I jigged up the blocks to drill the bolt holes. I pilot drilled with #40 followed by the #10 called out in the plans. Photo 3 shows how I jigged up the block on the forward skin stiffener. Unfortunately I drilled the left block to the right stiffener, so I'll be ordering a new stiffener.
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Set up to drill a support angle to the pilot's left brake pedal.

Set up to drill a support angle to the pilot's left brake pedal.

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Jig to drill bolt holes in the rudder pedal bearing blocks.

Jig to drill bolt holes in the rudder pedal bearing blocks.

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Jig to hold a bearing block in position to match drill the bolt holes through the stiffener.

Jig to hold a bearing block in position to match drill the bolt holes through the stiffener.

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