The Checkoway method helps you locate the baffle rivet holes on the Z-bracket flange, after the bolt holes are drilled on the other flange. I executed the steps the same way as Jason Beaver, by match drilling the bracket bolt holes using the spar as a guide. The problem is, the spar is thin so it's not much of a guide. The holes were drilled and reamed to #12 by hand (without a drill bushing).
I called Van's. They said it's OK to enlarge the holes up to #10 if needed, with the caveat that "they haven't done the analysis".
I can re-do the brackets and be more precise - use a drill block when match drilling, and bolt the nutplates down before riveting. That should help. I'm still not sure if it's necessary, given that these are not close tolerance bolts to begin with. The intent seems to be to use these as tension fasteners, not shear pins.
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Into the blue again, after the money's gone
RV-7A
Empennage complete minus glass work.
Wings kit in progress.
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