December 29, 2005 - Rudder Pedals
I couldn't prime the brake pedals today because it was raining outside.  However, I didn't need the brake pedals to be able to continue on with the rudder pedals.  First I put the rudder pedals together by inserting the nylon bushing block at each end.  It was a little tight at first -- I had to trim a little nylon away and file the ends of the rudder steel tubes. The bushing holes are slanted; it makes a difference which way they are set up.  
Then I took the bushing blocks off and drilled the #10 holes in each end where the AN-3 bolts go.  Usually I use a #12 bit for AN-3 holes.  I wondered why the drawings call for the slightly larger #10.  After awhile I realized the nylon really "grabs" the drill bit or bolt.  I think the holes need to be slightly oversized for this reason. 
A close-up.  I believe a drill press is required for this job.  With good clamping.  I don't think you could get a good, straight hole with the hand-drill. 
I'm sure I saved a couple of hours by simply following Dan Checkoway's method here instead of having to figure one out myself.  Instead of trying to matchdrill the stiffener angles inside the fuselage, he simply calibrated the stiffeners, removed them, and matchdrilled them on the workbench where they were easy to clamp and drill.  I clamped the bushing block 3 1/4" from the firewall and matchdrilled the two holes.  Then I moved the bushing block aft exactly 1" and drilled again.  Then again, for a total of 3 pairs of holes. 
You can see what I was doing a little better here. 
A good look at the "calibrated" stiffener. 
I clecoed the stiffeners back into the forward fuselage, put the rudder pedals into the bushing blocks, then bolted the bushing blocks onto the stiffeners in the forward-most position.  I was very happy with how they came out.  Hat tip to Dan. 
A close-up of the bushing block temporarily bolted to the stiffener.
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