This step was done while I was waiting for other things to cure over a few days. Its 2024 T3 angle cut into 2″ strips and shaped to make the lower attachment points for the front and rear harnesses.

I’ve just bought a second hand bandsaw and already have a linisher. The holes took a while and I made them at 6.3mm which is under 0.25″ or AN4 size however this was just too tight and I opened them out to 0.25″. Not worth forcing a press fit and risking damage. All the forces seem to be in compression rather than much shear and a tiny wiggle is acceptable given then will be floxed in anyway.

I took some care to get all the scratches out so there are no stress risers. I sanded down to 600 grit and then used scotbrite to finished off. Another pretty part no one sees once the plane is built.

2024-T3 angle cut in 2″ lengths

Holes drilled carefully

Cleaned up and shaped