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RV-7 Construction Log
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Date:  6-30-2012
Number of Hours:  7.70
Manual Reference:  pp 7-5, 7-6
Brief Description:  Fuel Tanks

I started the day by drilling the left tank ribs to the baffles and brackets. This is an operation I had missed after drilling the baffles and brackets using the "Checkoway" method. I then deburred all holes in the baffle, and the aft rib flanges.

Next, I fabricated, trimmed, and edge deburred the stiffeners for both tanks. I then final drilled them to the tank skins and marked them so they will be installed in the same locations at which they were drilled. I deburred the holes, but held off on dimpling until I can get a set of "substructure" dies.

Next I modified the inboard end ribs for the access plates. I started by cutting out the 5.25" hole in the rib. I found the center of the hole in the rib by taping a stiffener ring in place, then used my caliper set to a 2.625" radius to make several crossing scribe marks on the rib. The crossing point of the scribe marks is the center of the hole. With the ring still taped in place, I clamped the rib to a piece of particle board and the drill press table. Once I drilled the flycutter center hole, I adjusted the flycutter to just touch the edge of the ring, removed the ring, then cut the hole in the rib. I completed this operation for both inboard tank ribs.

I then drew the inner diameter of a stiffener rings on blank access plates (I will be using capacitance senders), used the drawn circle to center the plate on the rib hole, taped the access plates in place, and match drilled the screw holes into the ribs. I then clecoed the stiffener rings through the screw holes and match drilled the nutplate rivet holes. Per the plans, I dimpled the ribs (using tank dies to allow for sealant) and countersunk the stiffener rings.

Next I match drilled the 9/16 fuel pickup fitting holes into the blank access plates using the stock T-708 plates to locate the holes. I finished up by deburring all the edges of the holes, rings, and plates.
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Tank stiffeners drilled to right tank skin.

Tank stiffeners drilled to right tank skin.

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Using caliper and stiffener ring to find center of cutout.

Using caliper and stiffener ring to find center of cutout.

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Inboard end rib access plate modificatons complete for both tanks.

Inboard end rib access plate modificatons complete for both tanks.

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