9 Dec 04 - More Stuff with the Steps

I've looked at a bunch of RV steps before, and although there's probably not much aerodynamic difference, they tend to look better when flush rivets are used. Countersinking steel is an adventure, though, but we decided to give it a shot anyway. I think the best looking steps I've ever seen are on Brandon Dixon's airplane (here's a picture of the steps), but I don't think there's a way you could pull that off if you've got a quickbuild. I'm not real sure how Brandon pulled it off even with a standard-build kit.

In any case, today we countersunk the steps and match drilled all the holes for the bolts.

Step after being countersunk. We just used the normal countersink bit, but it took a bit more oomph than with aluminum.
Bolts in place. The hole in the bottom right of the picture is an "oops" hole. You don't need to drill that.
Steps after priming.

We're just following the directions here, except for countersinking the steps. Interesting to note, though, that (a) we didn't have to trim anything of the end of the steps to make them fit - according to the directions, they may be a little long. These ones were not. And, (b) it's a really tight fit to get the steps to fit into the plastic blocks. It's possible to get them in there without trimming the steps the other way - i.e., making the diameter of the tube smaller. I don't think you'd want to do this anyway, as you won't want to reduce the tightness of the steel in the plastic. You don't want that coming loose when you're standing on the step.

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