Alex's Vans RV-10 Build Log

Continuing on in section 29, I match drilled the holes in the F-1005E gussets into the F-1046 longerons. This was fairly easy using a right angle drill with a #30 bit, but I took time to ensure that  the gusset and longeron were positioned to ensure that the resulting holes in the longeron would meet edge distance requirements the drill was held perpendicular to the gusset while drilling from underneath I marked a line with tape 1/4" beyond the center of the holes in the gussets, and used that to help position the longeron along the gusset to ensure that the match drilled hole edges would be at least 3/16" in from the edge of the longeron Holes were match drilled and clecoed one at a time Success! After drilling and checking all holes, edge distance requirements were met I also made sure that the outer edge of the longeron sat flush with the flange of the F-1005C bulkhead Right side gusset holes drilled Left side gusset holes drilled the same way Next I match drilled the skin...

It was now time to move on to rolling of the fuselage side skins. All four side skins are shipped completely flat and require the bottom section that curves around the fuselage to be rolled by the builder. The plans begin by fabricating a clamping block to be used to hold the skin firmly against the workbench. I instead decided to use a 4ft length of steel angle that I had seen another builder use, so skipped creating the wooden block. I did, however, have to fabricate the roll construction angles. The plans don't specify which particular thickness of angle to use, but it turns out that a 6ft length of 3/4"x3/4"x1/8" angle is the one required. 6ft length of aluminum angle cut into two equal 3ft lengths and marked for cutting and drilling as per the plans Roll construction angles clamped together, ready to drill the initial #40 hole (after carefully marking its location) #40 holes drilled Remaining holes being match drilled from the skin into one of the roll construc...