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Ron and Alan took turns working on starboard bracket.

Ron and Alan took turns working upside down during fitting, filling and drilling starboard bracket. Spent a lot more time upside down than we would ever imagine.
Instead of mounting starboard side of module directly to firewall, figured there may be stuff in way to access screws. Thus decided to use a bracket and mount with 2 vertical screws you get to from inside cockpit. This meant 2 nutplates needed to be mounted on starboard footwell. OK, so we mounted a thin piece of G-10 JB KWIKed to bottom of footwell to act as a reverse cuddle plate and prevent rivets from pulling into phenolic footwell. JB KWIKed a piece of G-10 to top of footwell to better transfer load of small contact area nutplates. OK, drilled nutplates to 1/8". My longest rivets were 1/16" too short. Go to Richie's hangar and garbage pick four #6 flat head screws, OK, we need to drill nutplates slightly larger from 1/8". Only have a high speed drill bit in that size, no cobalt. Can only drill 1 hole then have to resharpen bit. If I would have tried for 2 holes, would have turned bit blue and ruined it.
Of course the screws were too long so they needed to be hacksawed down and a 45 degree bevel put on them. (BTW if you use 60 degree bevel you get left with a very thin and sharp first thread, 45 degrees works well).
Job done, fits and works great. Don't think Alan wanted to think much more about this starboard bracket, thus no picts of completed install. He finally did succumb to the pressure and got the 2 blind shots below.
Y10--01-24

Date: 01/20/2010
Size:
Full size: 2592x1944
Ron and Alan took turns working on starboard bracket.

Photo Properties

summary  details
Make NIKON Model E5900
Aperture Value f/2.8 Color Space sRGB
Exposure Bias Value 0 EV Exposure Program Program
Flash Flash, Auto-Mode Focal Length 7.8 mm
ISO AUTO Metering Mode Multi-Segment
Shutter Speed Value 0.02 sec Date/Time Wed 20 Jan 2010 10:09:04 PM UTC
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