Inspection Panels / Holes

Guys I want to install some inspection holes in the wings and was wondering what is the best method of cutting round 7" dia. holes. I had about 12 inspection covers and inner support rings made at the local water jet shop. The wing is assembled and riveted so it only adds to my problem. I find the fly cutter doesn't work well unless you can clamp to the drill press. Does anyone have a tip or a trick. The access cover will sit flush with the wing skin so I want the holes to be nice. As well what combination of Screws and Nut plates have you been using.
Thanks

Views: 1471

▶ Reply to This

Replies to This Discussion

Permalink Reply by David Gallagher on February 14, 2009 at 8:56am
Mark, I agree that the fly cutter wants to grab in and do bad things to your airplane. But I have had good luck with the fly cutter on something like this, but just not cutting the hole all the way through. Once I get a few revolutions with the fly cutter, the aluminum is sufficiently scored. I would trim close to the scored area with hand shears. Then I would take a pair of pliers and gently cold work the score until it breaks. File off the burrs afterwards. This is not unlike using an Olfa knife to score and bend a straight line. You are just working in the round.

Good luck.
Permalink Reply by Mark Colbeck on February 15, 2009 at 7:31am
Thanks David I am going to give it as try again this weekend.
Permalink Reply by Kevin McCune on February 15, 2009 at 9:05am
I have not tried this, its just a thought,how about turning the cutter backwards and then scoreing, less tendency to grab? And then cut and snap off. Like said I have not tried it yet so test it on something you don't care about first! Let us know how it goes, I have been wondering about post assembly access too.

Kevin
Permalink Reply by Jonathan Porter on February 17, 2010 at 1:47am
Get a Noah cutter - they are brilliant! (Noah - cuts arks).... it is an air driven routing bit with an attachment - and it is amazing. We do the cut outs for the arc on the side of the fuselage with it too - fantastic bit of kit from Aircraft Spruce...

After a nasty fly-cutter accident - both airplane and person got bruised - we needed to find a better solution - and this one came with recommendations form a friend in Canada.!!!

Part number 12-01977 NOAH ARC-360 HOLE CUTTER

RSS

New from Zenith:

Zenith Planes For Sale 
  

Classified listing for buying or selling your Zenith building or flying related stuff...

Custom Instrument Panels
for your Zenith:

Custom instrument panels are now available directly from Zenith Aircraft Company exclusively for Zenith builders and owners. Pre-cut panel, Dynon and Garmin avionics, and more.

Zenith Homecoming Tee:

Zenair Floats

Flying On Your Own Wings:
 A Complete Guide to Understanding Light Airplane Design, by Chris Heintz

Builder & Pilot Supplies:

Aircraft Insurance:

 
 

West Coast USA:

 
Pro Builder Assistance:

 

Transition training:

Lavion Aero

K&S Aviation Services

Aircraft Spruce & Specialty for all your building and pilot supplies!

How to videos from HomebuiltHELP.com

Developed specifically for Zenith builders (by a builder) these videos on DVD are a great help in building your own kit plane by providing practical hands-on construction information. Visit HomebuiltHelp.com for the latest DVD titles.

© 2024   Created by Zenith.Aero.   Powered by

Badges  |  Report an Issue  |  Terms of Service