---------------------------------------------------------- RV9-List Digest Archive --- Total Messages Posted Fri 05/21/04: 1 ---------------------------------------------------------- Today's Message Index: ---------------------- 1. 01:42 PM - Rudder, Aileron, and Flap wedge Jig (Bill Repucci) ________________________________ Message 1 _____________________________________ Time: 01:42:05 PM PST US From: "Bill Repucci" Subject: RV9-List: Rudder, Aileron, and Flap wedge Jig --> RV9-List message posted by: "Bill Repucci" Ok gang, I figured out an easy way to hold the wedges while countersinking them. I made a simple jig out of a piece of 2x4, and two other scraps of wood I had laying around my shop from a prior project (wine rack). I screwed two small "1 by" boards on top of the 2x4 using four screws in each piece. The width between them is equal to the width of the aluminum wedge. I then cut a slot out of the "1 by" boards down to the 2x4. The width of this cut is not critical but it has to be wide enough for the countersink tool to fit in. It is also handy for clearing out chips while you countersink. Next up was to take the small section of your wedge that was cut off to fit your part. Cut that section in half, drill, and nail it to the jig. I used small finish nails and set them below the surface of the wedge. Don't forget to route out a small hole in the 2x4 between the two wedge slices for the tip of the countersink tool. Now you can slide the drilled wedge down between the boards and its surface will be horizontal, making easy work of countersinking. Total time to build the jig, about 15 minutes. Time saved in countersinking, hours if not days (waiting for the replacement wedge to arrive.) You can see a picture of it at the bottom of my aileron & flaps web page, http://www.repucci.com/bill/ailerons.html. Bill R. RV-9 SN: 90737 N941WR (Reserved)