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RV-7 Construction Log
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Date:  4-16-2016
Number of Hours:  5.05
Manual Reference:  p. 8-11, DWG 26
Brief Description:  Finish Up Fitting Top Fuselage Skins

The first item on the agenda was fitting the F-709, the bulkhead between the aft end of the F-775 aft top skin, and the F-714 aft deck. I fluted the flanges with the predrilled holes, but the outboard flanges that are not drilled seemed to be straight enough to not require fluting.

Next, I removed the forward top skin for access to drill out the top two rivets holding the F-707 bulkhead halves together (which I should have left out in the first place) to allow for match drilling the F-707B angle clip. While the skin was off I drilled the two F-656 gusset plates to the longerons behind the F-706 bulkhead.

Once the skin was back on, I was able to fabricate the F-707B angle clip that attaches the F-787 stiffener rib to the F-707 bulkhead. The angle clip is a bit tricky, as it has to fit between the bulkhead top flange and the stiffener bottom flange, clear the future shop head of a skin rivet, AND maintain 1/4" edge distance for the rivet holes. I cut the angle just a bit longer than required, and then adjusted the ends with the belt sander and scotchbrite wheel.

After scratching my head about how to match drill the clip to the rib from the opposite side (instructions have you lift the right side of the skins, and the holes in the rib to match the clip are on the right), I just clamped the angle to the rib, then removed the rib with the clip and drilled it on the bench. It took a couple of tries to get a good clip, as I didn't have the first one clamped well enough, and it slipped while match drilling to the second hole. With a good clip clecoed to the rib, I reinstalled the rib and match drilled the bulkhead side of the clip from behind the F-707. This drilling order is backward from what the instructions call for, but seemed to work well for me.

I finished up the day by removing both top skins and drilling the F-656 gusset plates to the longerons behind the F-707 bulkhead.

Rivets Today: -2
Rivets Total: 11630
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Fit of the angle clip to the F-707 bulkhead.

Fit of the angle clip to the F-707 bulkhead.

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Fit of the angle clip to the F-787 stiffener rib.

Fit of the angle clip to the F-787 stiffener rib.

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All four F-656 gusset plates drilled to the longerons.

All four F-656 gusset plates drilled to the longerons.

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