Ivan's RV-7

Drilling the remaining F-705 bulkhead partsTimer icon3h

August 23, 2022

Today I continued drilling various parts of the F-705 bulkhead.

First, I made an arbor to mount a counter-sinking bit in a drill chuck. There were few a times when I wanted to counter-sink without the cage, so I thought this little adapter would come in handy. It's probably 1018 mild steel, which doesn't machine nicely if you don't make an effort (and I didn't -- as you can see by the surface finish 😁), which is what I have in my scrap steel supply box.

Arbor for the counter-sinking bit. With the bit installed.

Then I moved on to drilling various other holes, drilling all four sides of the bulkhead plus doublers together, and drilling seat stop parts to the top channel.

I used my rivet fan to drill the holes in the seat stop angle (if I understand its purpose correctly). I made a couple of small mistakes here. First, I drilled #30 (well, #31, I now drill all new holes slightly smaller, then use a reamer) instead of #40. However, the fan is drilled with #40, so I had to use silver clecoes to attach it. Since the initial two holes were #30, the fan wasn't positioned as precisely as it could have been. Second, instead of drilling through the fan (which is what fan instructions tell you not to do, though), I marked the holes with the sharpie, then center-punched and drilled them. This allowed a couple of holes to migrate slightly. It's all good in the end but could have caused issues with a more critical part.

Back seat stop angle.

The angle needs to be spaced at 0.125" from the channel, and they give you the spacer for that: the center bar F-705B is exactly that thickness, so that's what I used.

Mounting the angle for drilling.

The final result is not too exciting, but here it is.

The angle drilled to the channel.

The one part that is remaining for this bulkhead is an F-705K plate. It needs to be bent in the middle, and I don't have a bending brake to do so. So I keep thinking if I want to clamp it between two angles and "eyeball it" with the mallet or go to the Harbor Freight store and get their brake. Likely, the latter.