Dave’s RV-7A Building Log

Since the firewall parts need to be primed and the weather isn’t cooperating, I pulled out the parts for the F-704 center section bulkhead. They are very cool looking, solid and anodized. I carefully located and drilled out the holes for the snap bushings. Next, I clecoed the parts together including the spacer bars and put in the close tolerance bolts. Those things are a tight fit. I put them in the freezer first, but I don’t think that helped.

Next, I drilled all of the rivets holes to full size. I actually had more trouble getting the close tolerance bolts out, because the web was pulling away from the bar. Once I clamped that tightly together, the bolts dropped out pretty easily.

And finally I deburred all of the holes.

On Dan C’s web site, it says the fuselage instructions are sparse. Van’s must have updated them, because the instructions I have a pretty detailed so far. The funny part is they left out one important part. In the section called “Assembly of F-704 bulkhead”, nowhere does it say to rivet together the F-704 bulkhead. Must have been an oversight.

Deburred the rest of the firewall parts, dimpled the stainless steel sheet, and countersunk everything that needed it.

Finished final drilling the firewall, including the floor brackets and the recess. A couple of the holes on the recess didn’t line up very well, but it’s not a structural part. I just drilled them out, leaving them a little oblong.

When I took the firewall apart, I marked which parts need to be countersunk. It won’t be obvious once everything is apart.

I started deburring the firewall after that. The thin stainless sheet deburs almost like aluminum–just a little tougher.

Final drilled most of the firewall. This was a pretty easy step. I used Boelube and kept the drill speed low. One of the corner angles was super powdercoated, so I had to use silver clecos in the holes temporarily.

The wings are now basically waiting for Julie’s riveting assistance, so I’m moving on with the fuselage.

I fished out all of the firewall parts and started clecoing them together. A few parts need to be fabricated. In one case, this is as simple as just drilling a hole in a small piece of flat stock. It seems like when something needs to be fabricated from sheet or angle, Van’s usually provides something very close to the correct size.

I had to round a few corners, but it all fit together very nicely and looks cool. Julie was impressed, probably because it’s something other than a wing part.

There are a lot of instructions on the plans, so I’m doing the DanC thing and highlighting any tasks on there and checking them off when I do them.

I have a few more things to finish up on the wings, but I just couldn’t wait anymore to start on the fuselage. I fabricated the F-601J angles.