Cutting Longeron Notches in the Firewall

I spent about an hour cutting and sanding the notches for the 30×30 mm longerons. As described in the plans, the longerons meet the firewall at an angle. The critical dimension is measured on the forward face of the firewall — the engine side. The approach is to cut the firewall oversized first, then sand it down to its final width once it is mounted on the strongback.

The final width is 840 mm. I marked 5 mm of material to remove from the forward face at each notch, then gradually cut and sanded to achieve a snug fit. The work is not entirely finished yet, but it is coming along well.

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