Continued sub-panel

October 27, 2015 – I continued working on the sub-panel structure.

I needed to locate the center rib against the firewall. There are no instructions or guidance to do this, so I went ahead and drilled those holes. I took the top skin back off and slid the center rib out. I drew a centerline and drilled holes in the rib. I clamped it back in position, put the skin back on,  and drilled the holes through the firewall from inside and underneath.

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Back off with the top skin, I needed to drill the F7108B angle. This is a solid angle that reinforces the center rib. I also drilled a fastener hole where this angle attaches to the firewall.

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I clecoed the actual panel into place.

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There are some angles that need to be formed to fit the top curve of the panel. I fluted those, clamped them in place, and drilled the attach holes through the panel.

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There are also small angles that hold the panel in place on the outboard corners. The problem with drilling these was that the panel moves, so the angles move. I clecoed the top skin entirely in place, all the way down to the edges. This was a lot of work. I drew lines at the panel edge where it sits on the canopy rails. You can just see the lines against the lower surface of the panel in this photo:

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I drilled the entire skin to the structure.

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I also drilled the holes in the top flange of the firewall.

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Now that I knew where the panel would be, I removed the top skin. I clamped the angle in place using those drawn panel edge marks as a guide, then I drilled through the canopy rails.

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There are smaller angles that support the panel on the inboard side of the canopy rails. I clamped these in place and drilled the holes for those.

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I pulled the whole assembly off to the table where I will beburr everything.

Time: 4:40

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