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Lightening holes in ribs

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acepilot(at)bloomer.net
Guest

Posted: Sun Sep 23, 2007 2:34 pm Post subject: Lightening holes in ribs

Bought an OLD wing kit for my RV-4 recently.  The lightening holes need 

to be cut out on the ribs.  Does anybody have a pet method for 

accurately finding the center of the cutout...I will be using a fly 

cutter to do the cutting job.



-- 

Scott

http://corbenflyer.tripod.com/

Gotta Fly or Gonna Die

Building RV-4 (Super Slow Build Version)

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sbuc(at)hiwaay.net
Guest

Posted: Sun Sep 23, 2007 4:01 pm Post subject: Lightening holes in ribs

Scott wrote:

 	  Quote: 	
		   

 

 Bought an OLD wing kit for my RV-4 recently.  The lightening holes need 

 to be cut out on the ribs.  Does anybody have a pet method for 

 accurately finding the center of the cutout...I will be using a fly 

 cutter to do the cutting job.

 


	


Scott, measure the diameters of the lightening holes and make a set of 

round templates (cut out of poster board?) with a hole in the middle. 

Center a template on the rib in a lightening hole recess, make a mark in 

the center hole with a Sharpie, and crank up the fly cutter.



Be careful with the fly cutter, that thing can be deadly!



Sam Buchanan

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d-burton(at)comcast.net
Guest

Posted: Sun Sep 23, 2007 5:47 pm Post subject: Lightening holes in ribs

Hi Scott,



You can copy the drawing for the ribs or order a new one from Vans.  They

are only $3 or so for a full sized sheet.  Cut it out and lay it in the rib

to mark the centers.  



Just a silly suggestion:



DON'T get on a roll and cut lightening holes in ALL the ribs.  The tank ribs

and ends of the tanks don't get "lightened".  It's a hassle to fix them

after they have big holes in them, ask me how I know...  And no, it wasn't

me, it was Van's themselves.  I got one of the first set of wing kits that

came with the lightening holes done at the factory.  Whoever they gave that

task to did them all... tank ribs and all!



Dave



--

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acepilot(at)bloomer.net
Guest

Posted: Sun Sep 23, 2007 5:59 pm Post subject: Lightening holes in ribs

I understand!  I have experience with them...I used one to cut out all 

the holes in my new instrument panel on my Corben.  Good thing there 

were only about 8 holes I had to make!  



Scott

http://corbenflyer.tripod.com/

Gotta Fly or Gonna Die

Building RV-4 (Super Slow Build Version)



Sam Buchanan wrote:



 	  Quote: 	
		  



 Be careful with the fly cutter, that thing can be deadly!



 Sam Buchanan

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acepilot(at)bloomer.net
Guest

Posted: Sun Sep 23, 2007 6:05 pm Post subject: Lightening holes in ribs

Ooh, now there's some advice I can really use!!  Yes, I probably 

would've done just that!  I would have gotten the flycutter all set up 

and done every hole that was that size in one fell swoop.  Thanks for 

saving me from having to send MORE money to Van...



Scott

http://corbenflyer.tripod.com/

Gotta Fly or Gonna Die

Building RV-4 (Super Slow Build Version)



David Burton wrote:



[quote]



Hi Scott,



You can copy the drawing for the ribs or order a new one from Vans.  They

are only $3 or so for a full sized sheet.  Cut it out and lay it in the rib

to mark the centers.  



Just a silly suggestion:



DON'T get on a roll and cut lightening holes in ALL the ribs.  The tank ribs

and ends of the tanks don't get "lightened".  It's a hassle to fix them

after they have big holes in them, ask me how I know...  And no, it wasn't

me, it was Van's themselves.  I got one of the first set of wing kits that

came with the lightening holes done at the factory.  Whoever they gave that

task to did them all... tank ribs and all!



Dave



--

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webmaster(at)flion.com
Guest

Posted: Sun Sep 23, 2007 7:46 pm Post subject: Lightening holes in ribs

That's a great idea; I wish I'd thought of it.  I carefully did the first

rib and then used the stock I'd just removed to mark all the rest of the

ribs.  Even then, I'd clamp the rib in place and rotate the fly cutter by

hand to check where it was cutting.  By the way, that removed stock is

useful for making small bits.  Even the small holes yielded clamping pads,

bolt washers (for when I was bolting the longerons to the jig), and shims.

Waste nothing!



Patrick Kelley - RV-6A - working on canopy frame



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acepilot(at)bloomer.net
Guest

Posted: Mon Sep 24, 2007 3:02 am Post subject: Lightening holes in ribs

That's a good idea as well (big fender washers!!)!  Guess I better buy a 

metal "trash" bin to throw all the various bits of leftovers into.



Scott

http://corbenflyer.tripod.com/

Gotta Fly or Gonna Die

Building RV-4 (Super Slow Build Version)



Patrick Kelley wrote:



[quote]



That's a great idea; I wish I'd thought of it.  I carefully did the first

rib and then used the stock I'd just removed to mark all the rest of the

ribs.  Even then, I'd clamp the rib in place and rotate the fly cutter by

hand to check where it was cutting.  By the way, that removed stock is

useful for making small bits.  Even the small holes yielded clamping pads,

bolt washers (for when I was bolting the longerons to the jig), and shims.

Waste nothing!



Patrick Kelley - RV-6A - working on canopy frame



--

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sbuc(at)hiwaay.net
Guest

Posted: Mon Sep 24, 2007 6:09 am Post subject: Lightening holes in ribs

Scott wrote:

 	  Quote: 	
		   

 

 That's a good idea as well (big fender washers!!)!  Guess I better buy a 

 metal "trash" bin to throw all the various bits of leftovers into.


	


By all means save all your cutoffs and scraps; you will be fabbing all 

sorts of brackets, spacers, etc. I still have ten-year-old bits and 

pieces of RV-6 in my scrap box and several of my subsequent projects 

have RV-6 metal "flying" in them.  



Sam Buchanan

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jan(at)claver.demon.co.uk
Guest

Posted: Mon Sep 24, 2007 9:02 am Post subject: Lightening holes in ribs

I found it easy to just draw a couple of lines at 90 deg on the disk to cut

out - Got the centre with no problem that way... Did use a large compass to

draw a circle, just to make sure before getting the fly cutter out ...



I also made a small jig to clamp the rib in place during cutting ... and

watch you hands !!



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