Nicholas,

 

I centered the curve of the inspection plates around the elevator torque tubes and made the tops level.  Marking, drilling, de-coring, layups, nutplates.  I remember having pretty scratched up hands by the time I was done.

 

One thing I really screwed up was I countersunk the holes in the plates.  Not enough material left to hold the screw heads.  I had to make new plates from sheet aluminum, matching all my holes.  The second time I used a dimple die to create the countersinks in the plates.   It shouldn't be a problem to locate the dimple dies, just find an RV builder.

 

Getting the micro right isn't that bad except you can really trash the plates when you're sanding.

 

I don't have any finished photos except my finished, painted airplane, sorry.

 

Mike Easley