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.


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.


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.


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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