Today I started the installation on the Tunnel Access Panels by first clecoing the reinforcing plate bottom row onto the outside of the tunnel. I final-drilled the #40 holes around the perimeter of the plate and clecoed each hole as I drilled. Next I drilled the four corner holes with a #10 drill bit and then removed the reinforcing plate.
I then clecoed the cover plate onto the tunnel wall using the four corner holes and marked a cut line around the perimeter of the cover plate. I removed the cover plate and used my step drill to drill out the four corners in the tunnel wall.
I then used my Dremel Tool to carefully cut a line from one corner to another following the cut line I had created earlier. I carefully cleaned up the corners and edges until the cover plates fit perfectly. I final-drilled the twenty-four anchor nut attach holes with a #40 drill bit, before finally countersinking and deburring all the holes.
JerMo's RV-10 Project 