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Cutting an oval hole

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johngoodman

Joined: 18 Sep 2006
Posts: 530
Location: GA

Posted: Wed Sep 20, 2006 1:24 pm Post subject: Cutting an oval hole

I'm in the early stages of the Horizontal Stab and the plans show cutting an oval hole in two of the leading ribs for the trim cables. the plans show the hole to be 1.5" by .5". I can think of lots of ways to do it and each one gives me nightmares of a buggered job.

Any suggestions?



John

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Rick S.

Joined: 12 Feb 2006
Posts: 347
Location: Las Vegas

Posted: Wed Sep 20, 2006 1:42 pm Post subject: Cutting an oval hole

John, 



It's only for the passing of the trim cables and not that critical. I hand drew mine and just used a uni bit in the middle then nibbled it out with a nibbler and deburred. you can pass the trim cable through to se if you have any areas that may hang up. It is fun to route these when your done, actually it's a pain but I used a clothes hanger to pull it through.



Rick S.

40185



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Rick S.
RV-10
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jjessen

Joined: 22 Apr 2006
Posts: 285
Location: OR

Posted: Wed Sep 20, 2006 1:57 pm Post subject: Cutting an oval hole

John,



Go here ( http://www.jessen-RV10.com ) and go to Empennage, HS, Page 8-7,

then see step #4.  Click on the picture to get a better view.  



John Jessen

   #40328  



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Vern(at)teclabsinc.com
Guest

Posted: Wed Sep 20, 2006 2:31 pm Post subject: Cutting an oval hole

John,



One way is to drill a pilot hole and use a Demel tool to enlarge it. 



Vern (#40324)

Do not archive   



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pitts_pilot(at)bellsouth.
Guest

Posted: Wed Sep 20, 2006 3:48 pm Post subject: Cutting an oval hole

Another way is to use your Unibit to make two holes side-by-side and 

then trim out the rest.

Linn



Vern W. Smith wrote:



[quote]



John,



One way is to drill a pilot hole and use a Demel tool to enlarge it. 



Vern (#40324)

Do not archive   



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jjessen

Joined: 22 Apr 2006
Posts: 285
Location: OR

Posted: Wed Sep 20, 2006 4:21 pm Post subject: Cutting an oval hole

Linn has it right.  Just go to jessen-rv10.com and take a look at the series

of pictures in the thumbnails.  You get to the thumbnails by clicking on the

picture for that particular step under the HS section.  You'll see the

procedure, step by step.  Making the hole as shown in the plans is easy to

do.  



John Jessen

  #40328 Tailcone 



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John Ackerman

Joined: 19 Jun 2006
Posts: 130
Location: Prescott, AZ

Posted: Wed Sep 20, 2006 6:26 pm Post subject: Cutting an oval hole

John, in retrospect, this looks a lot worse than it is - like so many 

things on the 10.

I found that the left hole needs to be enlarged anyway, to keep from 

cutting the trim cable housing. Others probably know better methods, 

but I drilled a stater hole, then cut to the line with a carbide burr 

on a cheap ($5.00!!) die grinder from Harbor Freight and deburred.



John Ackerman

40458 wings



On Sep 20, 2006, at 2:24 PM, johngoodman wrote:



 	  Quote: 	
		   

 <johngoodman(at)earthlink.net>



 I'm in the early stages of the Horizontal Stab and the plans show 

 cutting an oval hole in two of the leading ribs for the trim cables. 

 the plans show the hole to be 1.5" by .5". I can think of lots of ways 

 to do it and each one gives me nightmares of a buggered job.

 Any suggestions?



 John



 --------

 #40572 Empennage

 N711JG reserved





 Read this topic online here:



 http://forums.matronics.com/viewtopic.php?p=62844#62844

Jack.Phillips(at)cardinal
Guest

Posted: Thu Sep 21, 2006 3:27 am Post subject: Cutting an oval hole

I'm at the same stage John, and will cut those holes tonight.  I plan to

use a hole saw and then elongate the holes with a rat-tail file.



Jack Phillips

#40610

N142KW reserved



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jdalton77(at)comcast.net
Guest

Posted: Thu Sep 21, 2006 5:28 am Post subject: Cutting an oval hole

A file didn't work so well for me - I used a step drill and a dremel tool. 

Worked great but was loud!

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Rick S.

Joined: 12 Feb 2006
Posts: 347
Location: Las Vegas

Posted: Thu Sep 21, 2006 5:34 am Post subject: Cutting an oval hole

Jack,



You like metal work huh? I hated using a file on sheet metal to enlarge holes mainly because it would grab and distort the hole but it was mostly my lack of technique and laziness to break out the dremel tool. Although I used the large fine vixen on the edges to remove the tooloing and clean up the edge. Two light passes then followed with the V-grove deburr tool and a light buff with the scotchbite made the aluminum sheet just as smooth and polished as you could ever want.



Rick S.

40185



do not archive



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johngoodman

Joined: 18 Sep 2006
Posts: 530
Location: GA

Posted: Thu Sep 21, 2006 8:11 am Post subject: Re: Cutting an oval hole

I'd like to thank everyone for the quick responses and good ideas. I've been looking at the Uni Bit thinking it was the solution, but now I'm gonna go for it. I really appreciated the JJessen web site - you have a new lurker

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