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duplicating holes

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carlossa52(at)gmail.com
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Posted: Fri Mar 16, 2012 3:03 pm Post subject: duplicating holes

Hello, folks  I am looking for some guidance on the process to duplicate rivet holes. I need to replace the leading edge skin (CH601-HD).

The old skin has already been removed from one wing (surprisingly easy) and the curved part cut, so I can use the flat parts as templates.

  The new skin already has four holes to get it positioned over the old skin.

Now I would appreciate some guidance from those that have done this (copy holes) before.  I have have hole duplicators from  Spruce (similar to this type  http://www.aircraftspruce.ca/catalog/topages/strapDuplicator.php ), but I  am thinking the inverted type (  http://www.aircraftspruce.ca/catalog/topages/strapDuplicatorPunch.php )  might help achieving more precision, as the old and new skins remain in close contact, and there is no deformation required to insert the tool in between.  Any guidance on the process and / or tools would be greatly appreciated. It took me a lot of time to polish these skins, and I'd hate (understatement!) to see them go to waste because one hole is a fraction of an inch off.    Thanks in advance for your comments / suggestions.

 Carlos Sa

CH601-HD, plans

  [quote][b]

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psm(at)att.net
Guest

Posted: Fri Mar 16, 2012 3:18 pm Post subject: duplicating holes

Hi Carlos,

     

     I learned a great trick from a retired airline mechanic (who has his     plane in the hangar next to mine).

     

     Get some clear plastic sheet (it doesn't matter what kind of plastic     so long as you can see through it - acrylic/polycarbonate are     fine).  Cut a strip that covers a portion of your holes.  Drill a     hole or two to attach it to the under layer of metal with clecos.      Then use your drill to drill holes through the plastic that match     the holes in the metal.  Now you have a perfect template for the     holes you want to match with the upper piece of metal.

     

     Place your template under the new sheet of metal and attach with a     couple of clecos.  Then you can drill the remaining holes using the     template holes to locate the new metal holes.  When you are all done     you will have a perfectly drilled set of holes in the new metal.  In     this case you don't need pilot holes - just drill them in the     plastic and the new metal to the final size.

     

     If you do this before removing the old piece of sheet metal you can     mark the offset from the edge to the holes.  Since you have already     removed the metal you will have to measure this.

     

     Have fun,

     

     Paul

     Camas, WA

     XL in flight test.

     

     On 3/16/2012 4:02 PM, Carlos Sa wrote:     [quote]Hello, folks                            I am looking for some guidance on         the process to duplicate rivet holes.       I need to replace the leading         edge skin (CH601-HD).

         The old skin has already been removed from one wing         (surprisingly easy) and the curved part cut, so I can use the         flat parts as templates.

         The new skin already has four holes to get it positioned over         the old skin.

         Now I would appreciate some guidance from those that have done         this (copy holes) before.              I have have hole duplicators from         Spruce (similar to this type http://www.aircraftspruce.ca/catalog/topages/strapDuplicator.php         ), but I am thinking the inverted type ( http://www.aircraftspruce.ca/catalog/topages/strapDuplicatorPunch.php         ) might help achieving more precision, as the old and new skins         remain in close contact, and there is no deformation required to         insert the tool in between.              Any guidance on the process and /         or tools would be greatly appreciated. It took me a lot of time to polish           these skins, and I'd hate (understatement!) to see them go to           waste because one hole is a fraction of an inch off.              Thanks in advance for your         comments / suggestions.

              Carlos Sa

         CH601-HD, plans

               	  Quote: 	
		  

	
     [b]

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larrycmcfarland(at)gmail.
Guest

Posted: Fri Mar 16, 2012 5:52 pm Post subject: duplicating holes

Hi Carlos,

You can rivet two pieces of steel strapping together at one end to align the straps (3 rivets).  On the opposite end, you drill the rivet diameter you need to get alignment of a single hole.

On the bottom strap, you put a rivet thru so the blind end extends below the strap.  Then, when you slip the lower strap with rivet below the sheet,

placing the rivet nub in the structure hole and then ink mark the replacement sheet thru the hole in the upper strap.  To get the alignment rivet sized to the rivet you need, pull the rivet in the strap and into a thick drilled flat so the diameter 

is held closer to the diameter needed. Then use a punch to knock the rivet out of the thick flat so the rivet protrudes well for alignment.  I did this on my main wing skins when the structure was drilled and I decided to change from .016 to .020.

and it worked well.

 

Larry McFarland   601HDS at www.macsmachine.com    

 

  

 

From: owner-zenith-list-server(at)matronics.com [mailto:owner-zenith-list-server(at)matronics.com] On Behalf Of Carlos Sa

Sent: Friday, March 16, 2012 6:02 PM

To: zenith-list(at)matronics.com

Subject: duplicating holes

 

Hello, folks



I am looking for some guidance on the process to duplicate rivet holes.

I need to replace the leading edge skin (CH601-HD).

The old skin has already been removed from one wing (surprisingly easy) and the curved part cut, so I can use the flat parts as templates.

The new skin already has four holes to get it positioned over the old skin.

Now I would appreciate some guidance from those that have done this (copy holes) before.



I have have hole duplicators from Spruce (similar to this type http://www.aircraftspruce.ca/catalog/topages/strapDuplicator.php ), but I am thinking the inverted type ( http://www.aircraftspruce.ca/catalog/topages/strapDuplicatorPunch.php ) might help achieving more precision, as the old and new skins remain in close contact, and there is no deformation required to insert the tool in between.



Any guidance on the process and / or tools would be greatly appreciated. It took me a lot of time to polish these skins, and I'd hate (understatement!) to see them go to waste because one hole is a fraction of an inch off.



Thanks in advance for your comments / suggestions.



Carlos Sa

CH601-HD, plans 	  Quote: 	
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  [quote][b]

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