I have pulled the WD-657 external steps out the third time and put them on my RV-7a, but I still cannot see how these are properly fitted.
I already have the holes cut in the outer skin, F-623, and F-625. The outer hole is a bit large (almost a 1/4" gap all around), while the hole through F-625 is tight (just to establish my baseline).
Two problems come up:
1) Looking at the gap at the bottom of the flange (of WD-657), there is a small gap (1/16") at the front portion, while there is a large gap starting at 1/4" at the rear portion. Part of that can be solved by bending that flange, but for the flange right next to the tube, no amount of bending will close that gap. The only way to close the gap near the tube is to rotate WD-657 around the vertical axis (by either extending the hole in F-625 forward or extending the hole in the outer fuselage skin backward). A lot of rotation and hole elongation would be required. That seems wrong.
2) The tube buts flat against the rib F-626. This adds to my problem, because it does not allow me to push WD-657 any deeper into the fuselage (and I think it needs to move at least 1/16 inboard, regardless of how I deal with my asymmetric gap). To solve this secondary issue, I can shorten the steel tube (irreversible and not very adjustable) or cut a hole into F-626.
How have others dealt with this situation?
Here is a picture of the gap between the flange of WD-657 and the fuselage side skin as seen from the below.
I already have the holes cut in the outer skin, F-623, and F-625. The outer hole is a bit large (almost a 1/4" gap all around), while the hole through F-625 is tight (just to establish my baseline).
Two problems come up:
1) Looking at the gap at the bottom of the flange (of WD-657), there is a small gap (1/16") at the front portion, while there is a large gap starting at 1/4" at the rear portion. Part of that can be solved by bending that flange, but for the flange right next to the tube, no amount of bending will close that gap. The only way to close the gap near the tube is to rotate WD-657 around the vertical axis (by either extending the hole in F-625 forward or extending the hole in the outer fuselage skin backward). A lot of rotation and hole elongation would be required. That seems wrong.
2) The tube buts flat against the rib F-626. This adds to my problem, because it does not allow me to push WD-657 any deeper into the fuselage (and I think it needs to move at least 1/16 inboard, regardless of how I deal with my asymmetric gap). To solve this secondary issue, I can shorten the steel tube (irreversible and not very adjustable) or cut a hole into F-626.
How have others dealt with this situation?
Here is a picture of the gap between the flange of WD-657 and the fuselage side skin as seen from the below.