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02-02-2014, 08:20 PM
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Join Date: Jun 2009
Location: Danville, IN (West of Indy)
Posts: 199
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Uncooperative Firewall Recess
I'm trying to assemble my firewall for match drilling. I'm having a heck of a time getting the pre-punched holes in the F-601K-1 recess to line up with the pre-punched holes on the F-601A-1 firewall. It seems that the upper most, 1/8" holes on the side flanges aren't far enough apart. However, this distance is set by the factory and I'm unsure how to get everything fitting well together.
I thought about cutting a slot in the upper corners to increase the flexibility of the part enough to line everything up. Anyone else dealt with this issue?
Thanks!
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Michael
Danville, IN
RV-7A Canopy/Finishing
N317PU Reserved
2020 Dues paid (February 2020)
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02-02-2014, 09:40 PM
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Join Date: Jan 2005
Location: Sedona Arizona
Posts: 349
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I just removed my flat piece and installed a recess piece I got from Van's as part of the engine conversion on my 7A. On mine the thing clecoed up with only a little fussing around. I just riveted it in place yesterday without any issues, other than those holes in the corners that need to be sealed up.
I did use some Fireblock Sealant between the recess and the firewall to help keep the fumes etc. out of the cabin.
You might experiment with some sort of pressure on the insides of the recess to see if you can get the movement you need with out too much distortion of the part. Careful use of a small hydraulic jack comes to mind...
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02-03-2014, 01:28 PM
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Join Date: Feb 2010
Location: Gardnerville Nv.
Posts: 2,828
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You think that's bad, wait untill you get to the tail cone. 
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7A Slider, EFII Angle 360, CS, SJ.
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02-03-2014, 01:39 PM
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Join Date: Mar 2007
Location: 45G, Brighton, MI
Posts: 1,867
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The following is from my log entry on this subject:
**********
Today I finished fitting and drilling the firewall recess to the firewall. I had to do quite a bit of "massaging" of the recess with a hammer and blocks to get it to fit the firewall.
I have a sheet from Van's separate from the plans and instruction manual stating that the recess can either be riveted to the front of the firewall, or on the rear between the firewall and stiffener angles. I'd like to do the latter, to provide a smoother surface on the forward side. The instruction manual suggests not installing the recess until later to provide access for installing the rudder pedal brace, but I don't see how to get the recess between the stiffeners and firewall after the stiffeners are installed. I'll have to do some research to figure this out.
While I had the firewall parts on the bench, I went ahead and deburred all the holes, and deburred the edges of the firewall and recess. Deburring the stainless steel is much slower and tedious than aluminum!.
**********
IIRC, the "massaging" I had to do involved moving the bend radius a bit to get the rivet holes to line up. If you look at the picture closely you can see a little bulge on the left side where the raised part transitions to the angle, but it isn't bad. My log indicates it took me 4 hours to get this thing to fit...

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Miles (VAF# 1238, Paid up as of 2018)
RV-7 TU 904KM (reserved)
Wings Fitted and Finish Kit on site
Construction Log
Picasa: Empennage Album, Wings Album, Fuselage Album
1955 Cessna 170B flying since 1982
'To get something you never had, you have to do something you never did.' -Unk.
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02-03-2014, 01:39 PM
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Join Date: Jan 2006
Location: Vonore, TN
Posts: 369
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Firewall Forward Plans
You may want to check the firewall forward plans, particularly the battery box and oil line plans, as several of the rivet holes become bolt and screw holes. And I wouldn't rivet on that recess untill almost all of your other firewall penetrations are done.
__________________
John Tierney
Vonore, TN
RV-7A - N777JT Flying
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02-03-2014, 09:49 PM
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Join Date: Nov 2005
Location: Asheville, NC
Posts: 2,692
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Miles and John are right on.
You can "fit" it, using the BMF hammer and blocks but don't rivet until the last possible minute. That hole is gold while putting in cockpit and firewall penetrating systems.
And yes the tailcone needed very similar persuasion. 
__________________
Bill Pendergrass
ME/AE '82
RV-7A: Flying since April 15, 2012. 850 hrs
YIO-360-M1B, mags, CS, GRT EX and WS H1s & A/P, Navworx
Unpainted, polished....kinda'... Eyeballin' vinyl really hard.
Yeah. The boss got a Silhouette Cameo 4 Xmas 2019.
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02-04-2014, 01:57 AM
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Join Date: Dec 2010
Location: Coal Point, Australia
Posts: 128
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hehehe......not wrong ive worked that little cherry out
Quote:
Originally Posted by bret
You think that's bad, wait untill you get to the tail cone. 
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After half assembling then disasembling about 7 times, its a tight little hinie...
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Regards,
Rob.
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M: (61) 401 578 700
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02-05-2014, 08:43 PM
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Join Date: Feb 2005
Location: Milton, FL
Posts: 8
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From the picture it looks like the recess is backwards.the flange on the firewall faces forward and the recess is indented into the cockpit. It gives the oil filter room. Flip the part 180 and install it on the opposite side and it will probably fit better.
Last edited by Mike Harris : 02-06-2014 at 04:47 AM.
Reason: Add word for clarity
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02-05-2014, 08:47 PM
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Join Date: Feb 2005
Location: Milton, FL
Posts: 8
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I suggest you leave it out until just before the engine is installed!
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