The second of my large hand reamers arrived in the post today. These things retail on Amazon for 112USD but I managed to pick up a new one for 10USD. This one is 1-1/2" and is needed to ream out the undercarriage socket reinforcing tubes to take the 1-1/2" OD sockets. This only took 2 hours of grunt work this time as the central sections of the reinforcing tubes were removed once the ends were reamed to size. So with the undercarriage sockets in place next step was to align the undercarriage legs.
A 1/4" pilot hole was drilled through the reinforcing tubing and the front of each socket where the 5/16" undercarriage retaining bolt would eventually go. These were aligned horizontally with the spirit level. A line was then drawn mid way up the top bearing surface of the leg so that this could be centred in the pilot hole. The fuselage was then placed on its right side and levelled fore and aft. The left undercarriage leg was then inserted and twisted to get the axle 1 degree from vertical using the digital level - this gives the required amount of wash-in for the wheel. the leg was then
clamped in position and match drilled from the pilot hole through the leg and out the back of the socket- easier said than done as the leg is spring steel and very hard - cobalt drills are essential and it takes more than one! I chose to do this by drilling 1/4" by hand first time and then opening the hole up to 5/16" - most of this latter step through the leg itself could be done using the drill press. Then the fuselage was turned over and the process repeated for the right leg. Finally, the bolts were inserted, the wheels put on the axles and the fuselage became a rolling chassis for the first time. This was definitely the time to get in and make aeroplane noises!
There is still a bit of welding to do to fasten the undercarriage sockets into the reinforcing tubes but that's a job for another day.