Drilled windshield roll bar

January 15, 2016 – I had a much better day today when it came to the airplane. I got the mounting holes drilled for the roll bar.

As I said in my last post, I really didn’t like where the pilot holes were located in the canopy rails; I thought they were a bit too close to the longerons and I risked damaging the longerons. So I decided to slightly pull the pilot holes inboard, so the outboard edges of the holes remained at or close to the edge of the longerons. I did this slowly, and final reamed the holes to the correct size.

The instructions called for back-drilling the roll bar from underneath. I didn’t like the access I had for that, so I used hole duplicators to drill the roll bar. Here was a typical setup. This worked great.

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I used drill bushings to mark the spacers that go underneath. I still have to take those holes up to size.

I marked the edges of the brackets on each side. I’ll trim these to clean up the appearance.

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Here’s an attempt to show how the access for the aft bolts is limited. I couldn’t even get the camera to see the bolt holes. You can just see that the camera is looking up, and it’s right under the roll bar.

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I clecoed the top skin on and put the center brace in place. I trimmed the end to fit into the receptacle on the roll bar.

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That receptacle then gets drilled for a 1/4″ bolt.

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I called it a day right there. I still have to drill the lower two holes for the center brace, and drill the spacers to the final hole size.

Time: 4:15

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