---------------------------------------------------------- Zenith601-List Digest Archive --- Total Messages Posted Fri 06/29/12: 5 ---------------------------------------------------------- Today's Message Index: ---------------------- 1. 09:42 AM - Zenith Banquet (Joe) 2. 03:17 PM - Drilling aluminum (Donald Lynam) 3. 03:40 PM - Re: Drilling aluminum (Thruster87) 4. 03:42 PM - Re: Drilling aluminum (Jay Bannister) 5. 07:19 PM - Re: Drilling aluminum (Mark Hubelbank) ________________________________ Message 1 _____________________________________ Time: 09:42:31 AM PST US From: "Joe" Subject: Zenith601-List: Zenith Banquet Zenith Banquet for Oshkosh EAA 2012 The Oshkosh Experimental Aircraft Convention is less than 4 weeks away! It's time to make plans to attend the Zenith Builder's Banquet for 2012. The Zenith Banquet for this year's convention will be held at Robbins Supper Club, 1810 Omro Road, in Oshkosh, on Thursday, July 26th. Wally at Robbins has been proud to have the opportunity to serve the builders of Zenith aircraft at Oshkosh for many years. Once again the menu will be incredible as usual. Slow roasted prime rib, smoked BBQ ribs, herb baked chicken, Grouper with lemon butter sauce, and all the extras that make Robbins one of the finest supper clubs in Oshkosh. The price of the banquet will be $20 per person. you can register at the Zenith display during the Oshkosh EAA convention. There is some major road construction in Oshkosh at the present time and the Highway 21 exit for Robbins may be closed. If you stop by the Zenith exhibit at Oshkosh, you can pick up a brochure with the directions for Robbins along with banquet information, and the bus times and route for the Oshkosh transit system showing the Oshkosh downtown and college RSVP required at the Zenith booth by Thursday noon. Space is limited and we've filled up the banquet room the past few years so please be sure to RSVP early. ________________________________ Message 2 _____________________________________ Time: 03:17:22 PM PST US From: Donald Lynam Subject: Zenith601-List: Drilling aluminum Hey Anyone=2C I know this is really a basic question=2C but I am constantly worrying abou t the shape of holes that I drill in the various aluminum structures and skin of my 601 with a hand-hel d drill. I have tried everything I can think of (4 different drills=2C new bi ts=2C backing up with wood block=2C different bit speeds) and I still get slightl y oval holes about 50% of the time. Am I worrying about nothing=2C is this just SO P when hand drilling a soft metal? Thanks for sharing your experiences. Don Lynam 601 XL ________________________________ Message 3 _____________________________________ Time: 03:40:13 PM PST US Subject: Zenith601-List: Re: Drilling aluminum From: "Thruster87" [quote="donaldlynam(at)hotmail.co"]Hey Anyone, I know this is really a basic question, but I am constantly worrying about the shape of holes that I drill in the various aluminum structures and skin of my 601 with a hand-held drill. I have tried everything I can think of (4 different drills, new bits, backing up with wood block, different bit speeds) and I still get slightly oval holes about 50% of the time. Am I worrying about nothing, is this just SOP when hand drilling a soft metal? Thanks for sharing your experiences. Don Lynam 601 XL > [b] Don't get too concerned with the drilling process just de-burr everything.[Drilling is much more critical in pressurized aircraft which yours is not] Cheers [retired aircraft mech.] Read this topic online here: http://forums.matronics.com/viewtopic.php?p=376873#376873 ________________________________ Message 4 _____________________________________ Time: 03:42:25 PM PST US Subject: Re: Zenith601-List: Drilling aluminum From: Jay Bannister Don, It has been known for a long time that you can't drill perfectly round hole s in thin aluminum with common twist drill bits, but that is not a problem. Since designers have known this for so long, their calculations for rivet and bolt size and spacing take this into account. Most of the rivet and small bolts are used in compression and not in shear anyway and the Avex ri vets we use do a good job of filling the holes once they are pulled. By th e way, you should torque all those little AN3 bolts as they are very easily over-torqued. When drilling thicker aluminum for closer tolerance bolts, the only way to get a round hole is to drill it a little under sized and re am it to the proper size. Hope this helps. Jay -----Original Message----- From: Donald Lynam Sent: Fri, Jun 29, 2012 5:19 pm Subject: Zenith601-List: Drilling aluminum Hey Anyone, I know this is really a basic question, but I am constantly worrying about the shape of holes that Idrill in the various aluminum structures and skin of my 601 with a hand-helddrill. I have tried everything I can think of (4 different drills, new bits,backing up with wood block, different bit speeds ) and I still get slightly ovalholes about 50% of the time. Am I worrying a bout nothing, is this just SOP whenhand drilling a soft metal? Thanks for sharing your experiences. Don Lynam 601 XL ________________________________ Message 5 _____________________________________ Time: 07:19:05 PM PST US From: Mark Hubelbank Subject: Re: Zenith601-List: Drilling aluminum Don, For small holes, generally having a good wood backing does the trick. For larger holes (1/4 inch and larger) a step drill works well in thin material (0.035 in and under). Irwin makes a number of different sizes, one is 3/16 to 7/8 in 1/16 steps for example. On 06/29/2012 6:12 PM, Donald Lynam wrote: > > Hey Anyone, > > I know this is really a basic question, but I am constantly worrying > about the shape of holes that I drill in the various aluminum > structures and skin of my 601 with a hand-held drill. I have tried > everything I can think of (4 different drills, new bits, backing up > with wood block, different bit speeds) and I still get slightly oval > holes about 50% of the time. Am I worrying about nothing, is this just > SOP when hand drilling a soft metal? > > Thanks for sharing your experiences. > > Don Lynam > > 601 XL > > * > > > * -- Mark Hubelbank NorthEast Monitoring 2 Clock Tower Place Suite 555 Maynard, MA, 01754 - USA mhubel@nemon.com 978-443-3955 ------------------------------------------------------------------------------------- Other Matronics Email List Services ------------------------------------------------------------------------------------- Post A New Message zenith601-list@matronics.com UN/SUBSCRIBE http://www.matronics.com/subscription List FAQ http://www.matronics.com/FAQ/Zenith601-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/zenith601-list Browse Digests http://www.matronics.com/digest/zenith601-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.