---------------------------------------------------------- Zenith-List Digest Archive --- Total Messages Posted Fri 03/16/12: 3 ---------------------------------------------------------- Today's Message Index: ---------------------- 1. 04:03 PM - duplicating holes (Carlos Sa) 2. 04:18 PM - Re: duplicating holes (Paul Mulwitz) 3. 06:52 PM - Re: duplicating holes (Larry McFarland) ________________________________ Message 1 _____________________________________ Time: 04:03:50 PM PST US From: Carlos Sa Subject: Zenith-List: duplicating holes Hello, folks I am looking for some guidance on the process to duplicate rivet holes. I need to replace the leading edge skin (CH601-HD). The old skin has already been removed from one wing (surprisingly easy) and the curved part cut, so I can use the flat parts as templates. The new skin already has four holes to get it positioned over the old skin. Now I would appreciate some guidance from those that have done this (copy holes) before. I have have hole duplicators from Spruce (similar to this type http://www.aircraftspruce.ca/catalog/topages/strapDuplicator.php ), but I am thinking the inverted type ( http://www.aircraftspruce.ca/catalog/topages/strapDuplicatorPunch.php ) might help achieving more precision, as the old and new skins remain in close contact, and there is no deformation required to insert the tool in between. Any guidance on the process and / or tools would be greatly appreciated. It took me a lot of time to polish these skins, and I'd hate (understatement!) to see them go to waste because one hole is a fraction of an inch off. Thanks in advance for your comments / suggestions. Carlos Sa CH601-HD, plans ________________________________ Message 2 _____________________________________ Time: 04:18:38 PM PST US From: Paul Mulwitz Subject: Re: Zenith-List: duplicating holes Hi Carlos, I learned a great trick from a retired airline mechanic (who has his plane in the hangar next to mine). Get some clear plastic sheet (it doesn't matter what kind of plastic so long as you can see through it - acrylic/polycarbonate are fine). Cut a strip that covers a portion of your holes. Drill a hole or two to attach it to the under layer of metal with clecos. Then use your drill to drill holes through the plastic that match the holes in the metal. Now you have a perfect template for the holes you want to match with the upper piece of metal. Place your template under the new sheet of metal and attach with a couple of clecos. Then you can drill the remaining holes using the template holes to locate the new metal holes. When you are all done you will have a perfectly drilled set of holes in the new metal. In this case you don't need pilot holes - just drill them in the plastic and the new metal to the final size. If you do this before removing the old piece of sheet metal you can mark the offset from the edge to the holes. Since you have already removed the metal you will have to measure this. Have fun, Paul Camas, WA XL in flight test. On 3/16/2012 4:02 PM, Carlos Sa wrote: > Hello, folks > > > I am looking for some guidance on the process to duplicate rivet holes. > I need to replace the leading edge skin (CH601-HD). > The old skin has already been removed from one wing (surprisingly > easy) and the curved part cut, so I can use the flat parts as templates. > The new skin already has four holes to get it positioned over the old > skin. > Now I would appreciate some guidance from those that have done this > (copy holes) before. > > I have have hole duplicators from Spruce (similar to this type > http://www.aircraftspruce.ca/catalog/topages/strapDuplicator.php ), > but I am thinking the inverted type ( > http://www.aircraftspruce.ca/catalog/topages/strapDuplicatorPunch.php > ) might help achieving more precision, as the old and new skins remain > in close contact, and there is no deformation required to insert the > tool in between. > > Any guidance on the process and / or tools would be greatly > appreciated.It took me a lot of time to polish these skins, and I'd > hate (understatement!) to see them go to waste because one hole is a > fraction of an inch off. > > Thanks in advance for your comments / suggestions. > > Carlos Sa > CH601-HD, plans > * > > > * ________________________________ Message 3 _____________________________________ Time: 06:52:44 PM PST US From: "Larry McFarland" Subject: RE: Zenith-List: duplicating holes Hi Carlos, You can rivet two pieces of steel strapping together at one end to align the straps (3 rivets). On the opposite end, you drill the rivet diameter you need to get alignment of a single hole. On the bottom strap, you put a rivet thru so the blind end extends below the strap. Then, when you slip the lower strap with rivet below the sheet, placing the rivet nub in the structure hole and then ink mark the replacement sheet thru the hole in the upper strap. To get the alignment rivet sized to the rivet you need, pull the rivet in the strap and into a thick drilled flat so the diameter is held closer to the diameter needed. Then use a punch to knock the rivet out of the thick flat so the rivet protrudes well for alignment. I did this on my main wing skins when the structure was drilled and I decided to change from .016 to .020. and it worked well. Larry McFarland 601HDS at www.macsmachine.com From: owner-zenith-list-server@matronics.com [mailto:owner-zenith-list-server@matronics.com] On Behalf Of Carlos Sa Sent: Friday, March 16, 2012 6:02 PM Subject: Zenith-List: duplicating holes Hello, folks I am looking for some guidance on the process to duplicate rivet holes. I need to replace the leading edge skin (CH601-HD). The old skin has already been removed from one wing (surprisingly easy) and the curved part cut, so I can use the flat parts as templates. The new skin already has four holes to get it positioned over the old skin. Now I would appreciate some guidance from those that have done this (copy holes) before. I have have hole duplicators from Spruce (similar to this type http://www.aircraftspruce.ca/catalog/topages/strapDuplicator.php ), but I am thinking the inverted type ( http://www.aircraftspruce.ca/catalog/topages/strapDuplicatorPunch.php ) might help achieving more precision, as the old and new skins remain in close contact, and there is no deformation required to insert the tool in between. Any guidance on the process and / or tools would be greatly appreciated. It took me a lot of time to polish these skins, and I'd hate (understatement!) to see them go to waste because one hole is a fraction of an inch off. Thanks in advance for your comments / suggestions. Carlos Sa CH601-HD, plans ------------------------------------------------------------------------------------- Other Matronics Email List Services ------------------------------------------------------------------------------------- Post A New Message zenith-list@matronics.com UN/SUBSCRIBE http://www.matronics.com/subscription List FAQ http://www.matronics.com/FAQ/Zenith-List.htm Web Forum Interface To Lists http://forums.matronics.com Matronics List Wiki http://wiki.matronics.com Full Archive Search Engine http://www.matronics.com/search 7-Day List Browse http://www.matronics.com/browse/zenith-list Browse Digests http://www.matronics.com/digest/zenith-list Browse Other Lists http://www.matronics.com/browse Live Online Chat! http://www.matronics.com/chat Archive Downloading http://www.matronics.com/archives Photo Share http://www.matronics.com/photoshare Other Email Lists http://www.matronics.com/emaillists Contributions http://www.matronics.com/contribution ------------------------------------------------------------------------------------- These Email List Services are sponsored solely by Matronics and through the generous Contributions of its members.