Steps 1, 2.   Cleco the F-1006 and drill out the #30 holes where indicated.  Follow this with the F-1028 in step 2. 

I'm still debating about the best strategy, whether to simply ream out the holes and forget clecoing the parts in place, or cleco first and ream/drill.  The F-1006 is rather floppy, so I decided this time to cleco and ream. 

02/20/06  -  20 minutes   

Steps 3.   Separate the F-1037 into its parts.  I used the Dremel again to do this. 

I cannot tell you how much I like the Dremel for this type of operation.  Very fast, very easy to control, don't have to hook up the compressed air, nice and thin cut, and if you use the surface of the cutting tool you can even smooth out the cut right then and there. 

2/21/06  -  20 minutes    Dremel

Steps 4, 5.  Drill out the #40 holes for the nut plate attachments in the F-1037 B & C parts.  Then machine countersink for AN426 rivets. Note that the blow-up says to do it on the opposite side of the picture they show you!  I assume that the picture is of the inside curve of the piece, so do this on the outside.  Odd instruction.  Just remember, as you can see in the picture, that the battery plate will sit on top of these and be attached with the nutplates, so the outside or top has to have the countersink.   

If anyone can tell me how to use the countersink tool, that's a lunch on me.  I've practiced and practiced with this thing and I'm still struggling.  I'm getting it to work, but if you've found it a little difficult, you're not alone.   

Then final drill the 12 holes indicated with a #12 drill bit.

2/21/06  -  20 minutes