I started working on this massive assembly by drilling the holes that will receive snap bushings to full size.
I then attached the F-704C-L&R Center Sections to the F-704A forward bulkhead and the F-704D-L&R Center Sections to the F-704B aft bulkhead. I assembled the components with clecos and put a NAS1307 close tolerance bolt through one hole on both top and bottom to align the parts exactly. On the aft F-704B, l located the F-704G shear bars with bolts and clamped them in place. I drilled the rivet holes to final size, and then disassembled, deburred and dimpled the parts. The rivets attaching the F-704G bars were installed with flush heads on the forward side.
I then fabricated the F-633 Control Column Mounts. I drilled the first bolt hole to the dimensions shown, then bolted the F-633 to the aft F-704. I squared it carefully and then back-drilled the second hole through the pre-punched hole in the bulkhead. After the holes were drilled, I trimmed away the area shown to save weight.
Time: 8 hours.
Leonard's RV-7A Build 