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n1cxo320(at)salidaco.com
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 Posted: Sat Feb 24, 2007 1:48 pm Post subject: How Did You...? |
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Re: replacement fuel tanks from Evan Johnson
After 12-years or so and finally finding loose slosh in my tanks I decided to have Johnson make me two of them rather than go through that mess again.
Here's my question: I can slip on the replacement tanks (they have 1/4" oversized skins) and accurately determine where the underlying nutplates are located and drill a pilot hole.
Then removing the tanks I can dimple the aft row of holes but the forward ones are what right now have me puzzled. The forward row of holes need to be machine countersunk, not dimpled. I can see that the cutter head's pilot "shaft" in my microstop countersink tool will 'bottom out' in the nutplate before the cutter has finished the proper cut, or even got a good start.
How did you folks get around this? I wondered if using the shop grinder to 'shorten' the pilot shaft a bit might work...other than that nothing has yet occured to me. (Fortunately it will be some time before I get the tanks so I have lots of time to figure this out.) I know others have faced this, and rather than reinventing the wheel so to speak I am asking for guidance. Thanks for any help.
John
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kboatright1(at)comcast.ne
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| Posted: Sat Feb 24, 2007 2:58 pm Post subject: How Did You...? |
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A couple of thoughts:
1) Have a buddy with a lathe turn down the pilot on the countersink to fit the inside diameter of the nutplates. The problem in this scenario is that you still need to drill the holes for the screws, and the nutplates will be in your way during that step too.
2) I really think you'll want to mark the tank on the airframe, but drill the holes and countersink 'em off the airplane. Going this route, after you marked the holes, you could attach the tank to a spacer shaped like the spar, then drill through the tank skin into the simulated spar. At that point, the hole in the false spar would serve as the guide for your piloted countersink.
I'm sure you're putting lots of thought into this. Once you decide how to approach the problem, it is probably worth talking it over with another experienced builder or a machinist before you start cutting aluminum.
KB
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