Stuck on page 24iS/U-02

[GVilleFlyer]

Hello everyone! Everything was going great until I got to the part where I slip the cleco'ed roll bar onto the losely-bolted cast bases (Figure 1 on attached plan page). No way! I eased the edge of the cast base (maybe a bit much-see photos) , I lubed it generously......but it doesn't seem to fit. I used a heat gun on the base of the roll bar and that allowed me to engage the roll bar onto the base- but it would not go down more than half-way.
Am I supposed to beat this on??? My calipers tell me the base is .5mm too wide, but that doesn't seem right. Is there a trick to getting this piece on there? What am I doing wrong?

Thanks!

 

[jsalley]

I used taps with a soft-head mallet, alternating sides. Took a while, since each side only moved about a millimeter at a time, but it eventually went in.

 

[Rv-12David]

I had the same experience. It’s a tight fit. As Jsalley says tapping it will help. I did the same while wiggling it back and forth. And remember to deburr and smooth the the inside of the roll bar as well.

 

[RV12M4]

Agree with rubber mallet process. Did you file the corners of the machined fittings down a bit? Boelube helped. Mine was a tight fit but the result was a very satisfying sturdy assembly.

 

[GVilleFlyer]

Yes, and thanks to all of you we lost our fear of the rubber mallet. We eased all the edges, including the internal edge of the long straps, polished all surfaces and applied a teflon film- then drove it all home with the mallet! Thanks again for all the help!