Hi Stan,
If you can convince your DAR ---
(Try to find one that does not have build experience on the Lancair IV?)
(if he even notices the holes?)
--- that these holes do not detract from the strength of the airframe-- then you move into the next step-- where you are a bona fide genuine test pilot.
All you are risking is your life and several hundred thousand dollars.
Seriously,
there are several principles that I found difficult to understand when I began working with composites. And by the way of my inspections --many others also.
Adding more material (glass or carbon) to a airframe makes it stronger.
Adding more resin makes it stronger.
If you take away a little material here you can add reinforcement there and it will be just as strong and maybe even stronger.
All of the statements are false. In fact-some are- just the opposite. The designer/ engineer looks at load path.
You can't cut the holes and put a reinforcing ring on the lip and expect it to carry the same load and flutter resistance.
Many years ago I worked as a technician in International Harvester Motor Truck engineering department in the stress lab. I learned enough to know that things are not always what they seem. They need to be proved by engineering data and by testing. Our problem with flight testing with the IV is that a failure is usually fatal.
I think we have blamed thunderstorms and weather decisions as they are a conveniant scapegoat.
I was number eight to fly. I built my airplane beginning in December 1991. I believe I had a superior adhesive system in Shell Teta. They were preaching "build light" in those days. Today putting several gallons of fuel tank sealers in the cabin is considered good practice! Upholstery is right out of the Lexus with the heaviest leathers and fabrics available. By way of contrast, Dairy Queen weighed 1995 pounds without finish paint (but with tons of primer and silicone resin) and just basic upholstery. (Seats and side panels). It has over 2500 hours and many many hours in the mountain West being kicked around.
But would I cut a hole(s) in the fuselage?
To install marginal airconditioner?? Not on your life.
Stan, if I were you, I would start by asking Lancair to provide engineering data. And I would ask LOBO to help.