I started my Saturday with drilling the F-705K and the F-705L to the F-705F channel.  These are basically the components that allow the seats to be reclined to two different positions for traveling in comfort at 200 mph.  Anyway, the F-705 F channel is the only component of the three that is pre-drilled.  The F705K and the F-705L basically come as strips of aluminum.

Not pictured, you have to take the F-705K and bend a 4 degree angle in it (come on Van's>>>  4 degrees ?!?!?!?). Who can bend to that precision out of their garage?  Regardless of the specification that Van's has, the idea of bending the F-705K is so that when the F-705K sits on top of the F-705L, one end of the F-705K will sit on top of the F-705F channel.  Don't worry if this doesn't make sense, I have pictures of it below.

First thing I needed to do is figure out how to locate the F-705K and L on top of the F-705F.  Van's instructions just state "DRILL THE F-705J ANGLE, THE F705K PLATE AND THE F-705L SEAT ADJUSTMENT SUPPORTS TO THE F-705F CHANNEL."

Okay, not much to work with.  I can usually figure out this what I need to do by looking at the prints and referencing builders web sites, but sometimes I would feel a lot more comfortable if I had a little more direction...

Here is how I got everything to line up:

• I drew a centerline on the F-705L, marked the first hole in 1/4" from the edge of the strip and drilled one #40 hole in that location.
• I clecoed the F-705L to the F-705F channel and lined up the center line in the row of pre-punched rivet holes.  I colored in the last hole with a sharpie marker and then removed the F-705L to ensure that I had the last hole 1/4" from the edge of the F-705L.
• I drilled all the F-705L holes to #40 using the F-705F channel as my guide.
• Removed the F-705 L to transfer a couple of holes to the F-705K.

I had to scratch my head a minute on where to locate the F-705L with respect to the F-705K. 

Here is the first #40 hole I drilled between the F-705L and K.  For placement of the F-705L, I positioned it up on the F-705K right where the F-705K the 4 degree bend was made.  The pictures below show better what I mean.

I basically drilled three holes between the F-705L and K.  One at each end and one in the center so that I could cleco those two parts to the F-705F channel and drill the remainder of the holes.

Here is how the F-705K & L sit on the F-705F channel.

Just another angle.

This picture shows my left to right alignment of all the pieces and parts.  I couldn't be happier.  Both left and right seat adjustments lined up this good.

While everything was clecoed together, I countersunk the F-705K for the flush rivets it will receive later.

I won't get into just how many times I have fabricated these angles....  Anyway, lets just say it was more than twice!!!  Anyway, one of the last things I had to do with the F-705G angles is to mill / drill a slot in angle to account for the canopy latch.  I chucked up a 3/8" end mill and put the angle in a cross vice mounted to the drill press.  With a little Tap Magic cutting fluid and some patience, I got some great looking slots cut into the angles.  The drill press doesn't make a very good milling platform, but it still did a significantly better job cutting the slot than I could have gotten with drilling a series of holes and doing lots of filing....

Here is shot of what my cross-vice setup looks like.  Until I get my bench mill, this did an acceptable job.

I clecoed the angle back into the F-705F channel and then filed the slot with all the parts installed to more or less make the hole  look uniform with all the parts.

Just another shot....

Here is what they angles looked like from below.  I had to dress up an area on this angle on the bottom left corner there.  On these angles, I didn't cut the 1/8" taper like Van's calls out.  I clecoed the angle to the F-705F channel and then sharpie marked the angle to taper the angle so it more or less lined up with the taper on the F-705F channel.  It isn't perfect, but it looks pretty good.

This  side, looks better, if only the picture was fuzzy.....

If I wouldn't have had to spend  3 hours re-fabricating botched F-705G angles, I would have gotten a lot farther.  Ooh well, not expensive mistakes, just time consuming.  Now I think I am going to move back up to the center section and finish some odds and ends up there.

I am getting really close to being able to prime and assemble something here.