Layout and planning. The existing square access hole you see is for the stall warner which I wont be installing. I will have AOA in my plane, which is far superior to a stall warner. But, this hole will be needed since I have such a tight space to work with. Both holes will be utilized in the event I have to access this ER tank. I will duplicate this layout on the right wing later.
Using a unibit, drill holes for your radii in the corners first, remember no sharp inside corners. I used 1/2" to try and mimick the existing design
As mentioned previously, the dremel with a cutoff wheel is my tool of choice for cutting stuff like this. Works great. Be very careful with this cut, no slips, use both hands so that bugger doesnt get away from ya!
Created a back plate for the nutplates in much the same way
Access covers dimpled and cleco-ed in place for a test fit. This space is only a little over 2" wide--that was all I could squeeze out of this geometry. The strategy will be to use the stall warner access hole for reaching in with tools and the new, skinny hole is needed to remove the tank access cover. Make sense? Looks good on paper...probably be drilling out rivets to remove the entire leading edge assembly if I have any major problems with this tank! ;) How careful do you think I will be with sealing that tank?? This is a weak part of the design for sure...a removable tank would be ideal.
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