The side panel of the quick build kit has to be removed by drilling out the temporary rivets. I used a battery drill with the clutch on the lowest setting. Note the top side has an angle fully riveted to the skin. Remove the rivets holding the angle to the top longeron on the port side.Locate the parts for the locking mechanism referring to Chapter 1 - p3. Deburr the stainless steel locking bar paying particular attention to the slots where the nylon guides operate.
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| The kit parts as supplied |
A series of holes and slots have to be are drilled through the top longeron allowing installation of the canopy actuator bar. This blog is to cover how I achieved the preparation of the top longeron to accept the actuator bar. For full detail refer to the factory plans.
Mark the center line of the longeron using a fine felt tip pen at the front and rear locations. Create a 4 mm hole through the tape on the front and rear mounting discs. Using those holes locate the front disc on its center's and stick to the face of the longeron then using the bar as a template repeat at the rear. The bar should be placed in the closed position i.e. located to the firewall. Using a transfer punch mark the longeron through the both discs - remove components - drill through on the center marks to 4 mm [5/32''].
Fit the remaining discs to the bar using the strip of tape to hold them in position. Re-Fit bar back with 4 mm screws at the front and rear. Using the transfer punch to mark the centers of the other discs & M6 nuts welded to the bar. Pull the bar fully back and repeat the location for the M6 nuts - remove bar - drill all holes 4 mm.
Cleco the side skin back onto the frame to transfer the location of the handle to the skin for the front cockpit handle only! Using a guide block with a 4 mm hole drilled square to its mounting face with a drill press. Locate the punch through each of the front handle holes then transfer the location to the skin.
Remove skin and drill through using a 4 mm drill on the center marks. Use the step drill enlarge the hole's to suit the handle.
Note: Select the correct step [size] on the drill and mark with tape to avoid stepping to far when drilling - this is a quick process.
Once complete use a chain file join the two holes then carefully file away the unwanted material. Polish all edges with 400 grit aluminium open cut paper.
WARNING - Mark all the holes with written ID on masking tape as it is all to easy to pick the wrong hole to enlarge. Do NOT write on any surface that is to be painted & visible in the cockpit as the ink in some felt tips bleeds through any and all applied barriers.
Fit the stainless steel plates using pop rivets to the longeron as per the factory plans. Reassembly and check operation of the trip bar then install the operating handles. Mark the center line of the longeron using a fine felt tip pen at the front and rear locations. Create a 4 mm hole through the tape on the front and rear mounting discs. Using those holes locate the front disc on its center's and stick to the face of the longeron then using the bar as a template repeat at the rear. The bar should be placed in the closed position i.e. located to the firewall. Using a transfer punch mark the longeron through the both discs - remove components - drill through on the center marks to 4 mm [5/32''].
Fit the remaining discs to the bar using the strip of tape to hold them in position. Re-Fit bar back with 4 mm screws at the front and rear. Using the transfer punch to mark the centers of the other discs & M6 nuts welded to the bar. Pull the bar fully back and repeat the location for the M6 nuts - remove bar - drill all holes 4 mm.
Cleco the side skin back onto the frame to transfer the location of the handle to the skin for the front cockpit handle only! Using a guide block with a 4 mm hole drilled square to its mounting face with a drill press. Locate the punch through each of the front handle holes then transfer the location to the skin.
Remove skin and drill through using a 4 mm drill on the center marks. Use the step drill enlarge the hole's to suit the handle.Note: Select the correct step [size] on the drill and mark with tape to avoid stepping to far when drilling - this is a quick process.
Once complete use a chain file join the two holes then carefully file away the unwanted material. Polish all edges with 400 grit aluminium open cut paper.
WARNING - Mark all the holes with written ID on masking tape as it is all to easy to pick the wrong hole to enlarge. Do NOT write on any surface that is to be painted & visible in the cockpit as the ink in some felt tips bleeds through any and all applied barriers.
Reference Manual Chapter 1 [page 3 / 30]
Clecos Types and Uses - EAA
Drilling Pilot Holes -EAA
Removing pop rivets - EAA
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