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Door shoot bolt pushrod fabrication

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clevelee(at)earthlink.net
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Posted: Thu Mar 27, 2008 12:52 pm Post subject: Door shoot bolt pushrod fabrication

Those who have gone  before,

  

 Currently attempting  to fabricate the forward shoot bolt push rods (10mm Al rod with slots, flats and  cross drilled holes).  Pride is keeping me from taking it to a machine shop  and having done quickly and 'properly'.  

  

 I am curious as to  how others have cut the slots. Hack saw is too narrow with insufficient  control.  Belt sander inside the hack saw slit is proving much to slow in  material removal.  Thinking about rotary abrasive  wheel...    Any creative suggestions for making the slot  other than a vertical mill?

  

 Thanks in  advance!

  

 Cleve  Lee

 A198 Mono XS   Jabiru 3300

 Currently in Market  Harborough UK

  

  

    [quote][b]

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craigb(at)onthenet.com.au
Guest

Posted: Thu Mar 27, 2008 1:25 pm Post subject: Door shoot bolt pushrod fabrication

if you  have the slot already there, then would suggest, about a 2mm drill bit and drill  a series of holes along the slot to open it up enough

 to get  a thin file in there, if you get one with teeth on the side it may make life  easier, alternatively an alloy or stainless blade for a  jigsaw

 would  work too, but harder to control than a file

  

 craig

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josok-e(at)ukolo.fi
Guest

Posted: Thu Mar 27, 2008 1:25 pm Post subject: Door shoot bolt pushrod fabrication

Hi Cleve,

You will get a lot of answers on this one. first of all: There is an update in the manual, slots are no longer advised, it's flattened ends now. But i am still proud of the hand filing i did. Lots of sweat and some blisters, but kind of nice to do. 



Regards,



Jos Okhuijsen

Visit -  www.EuropaOwners.org

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rparigor(at)suffolk.lib.n
Guest

Posted: Thu Mar 27, 2008 1:46 pm Post subject: Door shoot bolt pushrod fabrication

Hi Cleve



"I am curious as to how others have cut the slots"



I think the Factory is now providing flat stock as used in the shoulder

with modification, take a look at the latest install manual online, and of

shoulder width mod instructions.



I have in mine the poor quality round rods. I have 2 milling machines, but

instead of milling out a slot that will be not very strong, I milled a

flat on each side of the rod, and riveted 2 pieces of flat 2024 aluminium

on each side of the rod. One place to get material is www.mcmaster.com or

Aircraft Spruce. 6061T6 should work, easier to cut and machine, I had some

2024 laying around. Thx. for the tip Nev! I used a mill, did it incline so

there was a nice radius, you could in short order do it by filing.



Sorry I don't have any pictures.



To visualize, take your pinky and put a 2" long Popsicle stick on the top

of your pinky overlapping your pinky by 1", then put another 2" stick on

the bottom of your pinky. The 1" sticking out would of course be your

fork!



Don't make a sharp 90 degree corner where flat transitions to rod, it will

be a stress riser, make it 1/8" radius or larger. 



Ron Parigoris

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grahamsingleton(at)btinte
Guest

Posted: Thu Mar 27, 2008 4:18 pm Post subject: Door shoot bolt pushrod fabrication

Cleve

attached is a pik of Paul McAllister's door push rod. We did those by 

hand one Wisconsin winter

Graham



rparigor(at)suffolk.lib.ny.us wrote:

 	  Quote: 	
		   

 

 Hi Cleve


	


 	  Quote: 	
		   

 Sorry I don't have any pictures.

 

 To visualize, take your pinky and put a 2" long Popsicle stick on the top

 of your pinky overlapping your pinky by 1", 

 Ron Parigoris

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fklein(at)orcasonline.com
Guest

Posted: Thu Mar 27, 2008 5:11 pm Post subject: Door shoot bolt pushrod fabrication

Cleve,



With only a minimal tool inventory, I did some head-scratching, then I 

marked the slot w/ a sharpie pen, drilled a hole at the end of the 

slot, and proceeded to hacksaw TWO cuts which left a sliver at the 

center of the slot which falls away. A few minutes w/  a small flat 

file dressed it up fine. It was much easier than I thought it would be. 

Happily, that was the case because after trial fitting, I was not 

getting the shoot bolt penetration I needed as my forward rods were too 

short, and ended up making a second set.



Good luck,



Fred



On Thursday, Mar 27, 2008, at 12:50 US/Pacific, 

<clevelee(at)earthlink.net> wrote:



 	  Quote: 	
		   Those who have gone before,

  

 Currently attempting to fabricate the forward shoot bolt push rods 

 (10mm Al rod with slots, flats and cross drilled holes).  Pride is 

 keeping me from taking it to a machine shop and having done quickly 

 and 'properly'.  

  

 I am curious as to how others have cut the slots. Hack saw is too 

 narrow with insufficient control.  Belt sander inside the hack saw 

 slit is proving much to slow in material removal.  Thinking about 

 rotary abrasive wheel...    Any creative suggestions for making the 

 slot other than a vertical mill?

  

 Thanks in advance!

  

 Cleve Lee

 A198 Mono XS  Jabiru 3300

 Currently in Market Harborough UK

  

  



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raimo.toivio(at)rwm.fi
Guest

Posted: Fri Mar 28, 2008 4:35 am Post subject: Door shoot bolt pushrod fabrication

Fred,

  

 thank you for a nice memory like a short daytime movie  for me.

 That was EXACTLY what I did including a 2nd  set.

 It was quite challenging but  real fun.

 I was worried about those thin slot sides but so far they  are ok.

  

 Raimo OH-XRT

 http://mmniemi.aviation.fi/jami_07/europa/

  

 [quote]   ---

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