Friday, March 15, 2024

Roll Bar Assembly (3)

The outside leg of the attach bracket for the roll bar has to be shaved down to fit the taper of the fuselage.  I did that, then bolted down the attach brackets so I could start to get the roll bar in the right position in order to start drilling bolt holes.  I slipped the roll bar in place and took the vertical measurement from the top (at the center) down to the level of the fuselage longerons.  Even though my roll bar was the exact height called out in the initial fabrication instructions, for some reason it was almost 1/4" too tall when put in place.  It turns out the plans just don't show or mention that the outside portion of the roll bar needs to be cut away in order to allow it to nest down into the attach bracket. Left as it was originally, the rounded inside corner of the attach bracket angle held the roll bar up into the air quite a bit.  Before I hacked away at this part that took a long time to build, I double checked a few build logs online.  Yep, the outside portion has to be ground away.

Once I had gotten the roll bar to set down to the correct 17 7/8" vertical height callout, I clamped it to the attach brackets and drilled the aft holes.  For the aft attachment, countersunk screws/nuts attach it all together and are covered up by the side skin.


The front attach holes go through the skin itself, so I used the prepunched holes in the skin to locate and drill these.  These are different than the aft screws - the skin will be dimpled and the screws will go in from the outside to hold the forward lip of the skin in place.


The aft holes get #10 screws and the front holes get #8 screws.  The difference being that the front screw holes get tapped vs using nuts.  I misread the plans and drilled the same size hole in the attach bracket as I drilled in the skin.  That works fine when you don't have to tap threads!  Duh.  So my hole was too big to tap for #8s.  I probably could have just kept with #8s and used bolts, but instead I just made the countersink a little bigger and tapped the holes for #10 screws.  Of course I don't have any #10s the right length, so I'll have to add them to my shopping list.  There's nothing keeping me from moving on at this point though.