This is an image of the 'required' rudder cable hole. It's very tricky to drill but it's needed as the 804 is drilled out for 8's not an A.

The plans require that you relocate this hole, so you can see the hole that spans the angle is the 'new' hole, and yes the plans say to span the angle and avoid the rivet!!

This took ages to set up etc.

This is the underneath of the previous items. You can see there is very little room to manouvre. The hole 3/16 must be place 1/2" from the outer edge of the longeron so it's very tight indeed.

This is a tricky operation with the turtle deck inplace. It's a critical component, in an inaccesible place. Plans require great scrutiny to place the holes precisely and squarely through the parts required compliant with the MED. The Red item is the plastic base of one of my clamps! The swarf is just there to add dramatic effect.

This is the port gear assembly ready for fitting to the F-804. The bolt fits through the reamed weldment and gear leg.

Pop riveted the rod ends to the internally/externally primed control rods.

Another tricky little thing to do.

This is for a tiny shim and is double flush riveted to the weldment. It must be countersunk as the bolt head must rest flush to the weldment when fitted.

Port weldment and gear leg reamed to size. The swarf was a fair amount as you can just see the end of the reamer.

Just placed  6 non Nas bolts to help align the weldment to the centre spar.

The two dome shaped items are in fact rivets and the weldment must sit perfectly over these to help with the alignment process.










This shot is of the bottom and you can just make out two 'drift pins' helping in the alignment process prior to drilling the weldment to the left longeron.

You are required to place a small shim just behind where the bolt is, prior to final fixing.

This weldment seems to fit well!

Here you can see that I'm drilling out the 1/8th pilot holes and replacing them with 3/16ths ones.

You can see the brass 3/16th cleco's fitted. Don't forget to deburr all this work as it's quite swarfy!

Port gear weldment pilot  back drilled through skin, doubler, weldment with #30 prior to 3/16ths.

Tip. I fitted all temporary bolts through the weldment to hold in place prior to drilling out.

Good result as the weldment is nice and flus to the inner skin.