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sbuc(at)hiwaay.net
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 Posted: Tue Sep 25, 2007 1:34 pm Post subject: Fly cutters |
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The following posted for the benefit of builders who have yet to use a
fly cutter:
Like all power tools, the fly cutter has the potential for being
extremely dangerous. What makes it particularly hazardous to RV builders
is that the project may be the first time a fly cutter has been
encountered by the builder. True, common sense will dramatically reduce
the odds of an accident, but when a fly cutter and the material being
cut gets loose, the results can be catastrophic.
Somewhere on the web a few years ago a photo circulated of a mangled
hand that had a most unfortunate encounter with a fly cutter. The points
presented in Paul's post below are certainly valid and detail a great
way to tame the fly cutter.
In my experience the two most common errors in using the fly cutter are
failing to TIGHTLY clamp the piece to the drill press table with a wood
backing and failure to use a SHARP fly cutter. If the cutter gets dull,
it WILL snag in the cut, hopefully stalling the drill press, but if the
work isn't tightly clamped, and the drill doesn't stall, the whole deal
becomes a whirling guillotine.
Another hazard is failing to stay clear of the cutter. Depending on the
speed of the drill press, the cutter bar can be nearly impossible to see
and dangling clothing or careless fingers can instantly be pulled into a
really bad situation.
Yep, a fly cutter can be used with a hand drill.....I've done it when
needing to add a hole to a panel in an assembled plane (didn't enjoy the
process, however), but this only increases the possibility of having an
accident. It is easy to let the cutter get less than perpendicular to
the work and then there are problems (see above).
So, be careful, work slowly, keep the work securely clamped and the
cutter sharp, and all should go well. Violate any of these guidelines,
and your building progress may be uninterrupted while you learn to use
fewer fingers.
Let's be careful. 
Sam Buchanan
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Joseph Larson wrote:
| Quote: |
You know, I never had a problem with my fly cutter, and I was a lot less
cautious than this. I normally run it on the slowest setting on my
drill press, but I even used it with a variable-speed hand drill. With
the hand drill, I was still careful and I went slowly.
When using a hand drill, you can feel when something isn't going right
and can adjust accordingly.
So, I'm not sure what the dangers are, as long as you respect the tool.
Did I just get lucky?
-Joe
On Sep 25, 2007, at 2:08 PM, PSPRV6A(at)aol.com wrote:
> Fly cutter hints: Yes, The fly cutter can be a loose cannon, but
> done right it can be tamed. First, mark all the centers carefully and
> drill (not with the fly cutter) 1/4". Drill the ribs undersize and
> ream to 1/4" if you have a reamer. Fit the fly cutter with a 1/4"
> SMOOTH pin NOT a drill bit. Grind the cutter blade to a narrow cut,
> about .050 at its outer edge. Use only about a 7 degree clearance angle.
> Set up a sturdy board clamped to your drill press table and drill
> about 15/64 and then "burn" to 1/4" with a smooth pin. A few drops of
> oil in the hole will help. This will give a firm outboard pilot for
> fly-cutting. Now mount up your fly cutter and float the SMOOTH pilot
> pin into the rib hole and into the board. Clamp the rib to the board
> and only now start the drill press. Use rather slow speed, but you
> may feed quite firmly until near breakthru. A touch of oil will help
> but is not always needed. This makes fly cuttin a piece of
> cake!
> Good luck,. Paul S. Petersen
>
> Minnetonka MN RV6A nearly complete with son Eric
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jfogarty(at)tds.net
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| Posted: Wed Sep 26, 2007 8:02 am Post subject: Fly cutters |
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General information, do not raise the fly cutter after you have cut through
the aluminum with your drill or drill press still running. You will have a
flying disc heading for a perfectly good fuselage, VS or other airplane
parts, including the pilot. I had a disc hit the VS and fortunately I did
not have damage, thank you lord.
Jim
RV9a
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