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nfivesl(at)yahoo.com
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 Posted: Thu May 11, 2006 10:24 am Post subject: Fly Cutter /Drill-Nibble-Snip-File (sorry this is long) |
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There are 45 flanged holes in the 601XL project - 19
in each wing, one in the middle spar, one in the rear
seat panel, two in the instrument panel support, one
in the aft fuselage bulkhead and two in the middle
bulkhead. I probably missed a few.
Randy is a plans-builder. All seriousness aside,
cutting 45+ holes with a nibbler, snips and file would
put him finishing some time in early 2016 not to
mention carpel tunnel syndrome infliction. I suggest
taking another look at the fly cutter approach unless
you are a kit builder only putting a few holes in your
wings for inspection holes.
To date I've cut all 45 of my permanent holes and
several practice holes with one of two fly cutters.
Of all the holes I cut, only one was was a reject
because I got too aggressive with the flanger which
caused a small crack (notice the rib hanging on my
pegboard). I've used the weighted fly cutter and the
double-knife el cheapo with good results. The key is
to go slow, clamp everything down before starting and
keep the blades sharp and clean.
Here's the weighted one after making a hole:
http://www.cooknwithgas.com/6_8_03_Flycutter.jpg
If you keep it sharp and keep the shavings off the
blade it works fast and makes a nice hole. The real
problem is the limited reach of a drill press. On the
rear ribs, my drill press didn't have enough room
between the post and the drill bit center. Luckily I
decided early in the project to buy a small mill/drill
that has a much longer reach and acts as a drill press
with the drill chuck mounted.
In all honesty, I can't see how I could have come this
far without the little mill/lathe/drill machine so I
recommend to all plans-builders that you get one
sooner than later. I use it all the time when I least
expect to. For example - I had some slop in my yoke
from side to side. I've heard of some factory torque
tubes with this problem but I had built mine from
plans. I removed the bushing that was called out in
the plans (a piece of 1/4" X .028" tubing). I turned
down a bolt to the proper size that fits snug inside
the hole, then bore-drilled it with the drill chuck
mounted in the tail stock of my little machine. Now
there's no slop and my ailerons won't have any slack
in them. I could mention several other instances of
this machine making great parts for the airplane.
I've never used a metal lathe or mill before this
project, so anybody could do it.
Back on subject - once you get it set up, drilling
holes in the ribs with a fly cutter is easy with the
right setup. You can do all of your rib holes in one
evening instead of six months.
Happy Building,
Scott Laughlin
Installing a BRS on my Corvair-powered 601XL
http://www.cooknwithgas.com/
_____________________________________________________
--- Paul Mulwitz <p.mulwitz(at)worldnet.att.net> wrote:
| Quote: |
I found plain old tin snips to do a reasonable job.
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Geoff Heap
Joined: 12 Jan 2006
Posts: 266
Location: Lindenwold, New Jersey
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| Posted: Thu May 11, 2006 11:34 am Post subject: Re: Fly Cutter /Drill-Nibble-Snip-File (sorry this is long) |
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Right on Scott. I'm going to repeat something you said. CLAMP THE PART and cut slowly. Thats how I did the two holes that I made with a flycutter. When I plans made my ribs however I used my C.N.C. Mill. Sorry.......Geoff
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