Repairing a hole in the fuselage
 

I had the opportunity this week to wander around many of the fabulous RV's that were at Oshkosh. I admit to peeking underneath, seeing how one thing or another was done on your plane. I peered into planes to see what color you used. One thing I would still like to do is check out rudder locations. I'll post that request in a different thread.

This thread is for the mistake that I found out I have made. I have come to the definitive conclusion that steps are not needed on a tail wheel RV7. Unfortunately I have bored two beautiful holes in the side of the plane for the steps that I was going to put on. As I see it, I have three choices.

1. Use fiberglass to fill the hole.
2. Create a metal patch and use some body filler to fill in gaps.
3. Order two new side skins.

What I'd like to know is if anyone else has had to face this and how did they overcome it? Are there any options that I am missing? The new side skins seem like the most pain free solution, but they have already been rolled and all my holes have been match drilled, though not dimpled.

My solution
 

I started building a 7A but changed my mind and switched to a 7. Like you I had already drilled two very nice holes in my fuselage for steps. I filled mine by cutting two blanks to fit the opening. Unfortunately I did not save the cutouts when I cut the original holes. I riveted the new blanks to a back plate and riveted that to the fuselage. One problem you will encounter is the curve at the bottom of the fuselage right where the hole is located. I tried to bend the blank as close to the curve as possible. It is certainly not perfect. I plan on using a micro-ballon slurry to fill and finish this area. Below is an image of the finished work

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Another alternative you might consider is shortening the steps and installing them anyway.

Especially usefull for some elderly/handicapped folks.:)

Isn't that spot just begging for the statement that could be made by covering it with a "NO STEP" placard?? :rolleyes:

Nice idea, hadn't thought of that.

One Step Further
 

Scott is right on! I have thought about doing this to my steps. I would do just what Scott did but prep it for a coat of body filler to make it totally invisible. To do this I would use a .024 round circle like Scott so it sets a little low. Then after I dimple the fuselage skin, I would then countersink the dimple to make the rivet set about .001+ lower than the side skin. I can't tell from Scott's pic if he did this or not. When you put on the body filler there is no chance of anything sitting proud and thus an invisible repair. Another option is to countersink only, since it is not a structural repair.

Steve "The Builders Coach"

Or; "Retracted step to be accessed only by the owner of this aircraft!"

Shorten step
 

I searched my bookmarks for a link to someone that had shorten their steps. I can not find it, probably deleted it when I filled mine. The process would be easy enough to remove the portion you step on and then reduce the over all length and re-weld the step.

Given the same decision again I would shorten my steps and install them. But I am certainly not going back to that solution now. I would like to finish this plane some day.

I didn't shorten steps, but I designed a "straight" step that has no welded joints, for my RV-6. They come straight out of the fuselage just behind and aligned with the flaps.

Mel, got any pictures of that? I'm thinking I may want to do the same for my wife.