Dec 8 2002 - Next up are the dreaded gear boxes that everyone seems to have fits over. The first step is to fit the F802G to the F822 bottom skin. Since the F802K Z angle is match drilled, I used it to drill the 802G as shown and then both parts are match drilled to the bottom skin.

Just draw a center line from the one hole already drilled in the 802G, cleco together, line the rest up, and drill away.

Next up is to get the WD822 weldment fit. I chose a different method than called for and used an extra large c-clamp and several smaller clamps to get the weldment fit tight and aligned. This has to be better than trying to hold it by hand and having a helper drill holes.

Here is an interior view of the clamped weldment. The fore-aft alignment is fixed by the F802G and a spacer that simulates the 802A bulkhead. The cleco side grip is holding the spacer (not visible) in place between the 802G and weldment.

Drill the side facing holes into the F843 longeron, disassemble, debur, and re-assemble. Then drill the two top holes through the longeron and into the weldment. You now have perfect alignment to the longeron and 802G angle.

Fit the 820 skin and F844 longeron back and drill the remaining holes.

Now for the 802A and B bulkheads. With the spacer removed, fit the bulkhead and drill the 802G holes, the holes into the weldment, and the holes down the side skin along a centerline. Repeat for the aft bulkhead, drilling those holes with the 802C cover clecoed in place. Drilling the 802H angle is then simple.

Fitting the gear boxes turned out to be a non-problem, at least compared to some other areas that I have had trouble with. Everything fit as expected - maybe kit revisions have improved this area. We'll see how the riveting goes after everything gets disassembled, deburred, and primed.

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