RV-9A: F-704 Bulkhead - 4/13/2008
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 Started work on the F-633 Control Column Mounts
I started off by drilling the top hole according to the instructions. Then I temporarily stuck a bolt through the hole to hold the mount in place. After getting the mount situated at a perfect 90 degree angle to the bulkhead, I drew a line down the side of the mount. This will me keep the mount where it needs to be for drilling the bottom hole.
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 Drilled the bottom hole
I clamped the mount down and slowly drilled the bottom of the mount, using the bulkhead hole as a drilling guide.
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 Checked out the fit
I put the bottom bolt in the new hole just to check the fit. No nuts yet.
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 Trimmed away the excess
It took a while to draw the lines onto the mounts. I cut the excess off with my bandsaw and then smoothed everything down with my Scotchbrite wheel.
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 I went ahead and bolted the mounts in place
I was really confused by the instructions, but decided that it made sense to go ahead and permamently attach these mounts.
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 Temporarily put on the Wd-610 control column
At this point I'm not sure why I'm putting all this together or if I'm supposed to put it all together, or what get's final bolted. ARRRGGG!
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 Trimmed the Wd-611/612 control stick bases and brass bushings
In order the control stick bases to and brass bushings to fit inside the ends of the Wd-610 control column, they have to be trimmed off a little. I used my Scotchbrite wheel to do the trimming. Even though the instructions didn't say to, I left the brass bushings just a tad longer than the control stick collar that surrounds them.
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 My favorite part, drilling out the brass bushings
I went back and read my notes on the brass bushings for the wings. I drilled a 25/64" hold in some scrap 2x4s. Then I wrapped painters tape around one end of the bushing and drove the bushing into the hole of the 2x4 with a rubber mallet. Then I coated the drill bit with oil and starting drilling, using the slowest setting on the drill press. I really took my time and went very slow. Both bushings came out great.
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 To bolt or not to bolt. That is the question...
The instructions say: "Once the control stick assembly is fitted it may be removed as a unit." As a Unit? I don't think so. If you bolt the Wd-610 control column and Wd-611/612 control stick bases together, then you can't get the bolt in or out that attaches the Wd-610 control column to the F-633 control column mounts on the bulkhead. The Wd-611/612 control stick bases interfere with that bolt. The way I see it, later in the project, the Wd-610 control column will have to go on first, then the Wd-611/612 control stick bases will bolt on. There is no way to store the Wd-610 control column with the Wd-611/612 control stick bases final bolted as a unit and be able to attach this assembly to the mounts later. You'll notice in he picture that I loosely put the bolt, washer and lock nut together (held together with tie-wire) in the separate parts so I can store everything away and not have to go search for this parts again later.
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 Same with the mounts
Turns out that the only bolts that were tightened in place where the bolts that hold the mounts to the bulkhead. I went ahead and loosely put the control stick bolts in the swivels on the mounts. Just to keep from going on the "Hunt for Read October" for bolts and nuts later.
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