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JerryHey

Joined: 05 May 2007
Posts: 30

Posted: Tue May 08, 2007 12:18 pm Post subject: Day one

Hi guys,  I promise I won't load this list up with every little move  

but today I ordered my first sheet of Aluminum (4' x 8' x .025") and  

built a hole flanging tool.  The tool cost about $3.50.  I have  

nothing to try it on, but here it is.



   I am  scratch building but might buy a part or two if the going  

gets too tough. I plan to cut 2' x 4' off the sheet I just ordered to  

use for practice.



Question,  How critical are the diameters of the lightening holes?    

I can buy hole saws that are quite close in size but not exact.   

Morse offers saws in 1/8" increments.     Thanks,



Jerry Hey

STOL 701

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carlossa52(at)gmail.com
Guest

Posted: Tue May 08, 2007 1:24 pm Post subject: Day one

Welcome aboard, Jerry



About the lightening wholes, I would ask ZAC - I guess a small variation is ok, but you need to check. They blessed a change I made on that "department".

As for cutting the holes, wouldn't a single fly cutter be cheaper instead of multiple hole saws? 



Good luck



Carlos

CH601-HD, plans

Montreal, Canada



On 08/05/07, Jerry Hey <jerryhey(at)earthlink.net  (jerryhey(at)earthlink.net)> wrote:[quote]Hi guys,  I promise I won't load this list up with every little move 

but today I ordered my first sheet of Aluminum (4' x 8' x .025") and

built a hole flanging tool.  The tool cost about $3.50.  I have

nothing to try it on, but here it is.



   I am  scratch building but might buy a part or two if the going 

gets too tough. I plan to cut 2' x 4' off the sheet I just ordered to

use for practice.



Question,  How critical are the diameters of the lightening holes?

I can buy hole saws that are quite close in size but not exact. 

Morse offers saws in 1/8" increments.     Thanks,



Jerry Hey

STOL 701



[b]

- The Matronics Zenith-List Email Forum -

Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:

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JerryHey

Joined: 05 May 2007
Posts: 30

Posted: Tue May 08, 2007 1:24 pm Post subject: Day one

Looking further at the Morse site, I found they had metric hole saws  

in all the sizes needed.  I ordered 65mm, 95mm and 114mm.  Jerry

On May 8, 2007, at 4:15 PM, Jerry Hey wrote:



 	  Quote: 	
		   Hi guys,  I promise I won't load this list up with every little  

 move but today I ordered my first sheet of Aluminum (4' x 8' x . 

 025") and built a hole flanging tool.  The tool cost about $3.50.   

 I have nothing to try it on, but here it is.



   I am  scratch building but might buy a part or two if the going  

 gets too tough. I plan to cut 2' x 4' off the sheet I just ordered  

 to use for practice.



 Question,  How critical are the diameters of the lightening  

 holes?   I can buy hole saws that are quite close in size but not  

 exact.  Morse offers saws in 1/8" increments.     Thanks,



 Jerry Hey

 STOL 701

 <P1010001.jpg>

- The Matronics Zenith-List Email Forum -

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p.mulwitz(at)worldnet.att
Guest

Posted: Tue May 08, 2007 3:37 pm Post subject: Day one

Hi Jerry,



I am a kit builder, but I have made many small parts for my plane.  I 

guess that qualifies me to make a few comments on your questions.



First, on the lightening holes - I am sure 1/8 inch variation is 

OK.  That is within the general distance tolerance for all parts on 

the design which (if I remember correctly) is specified in the 

builder's manual as 3 mm.  This much variation on lightening holes 

will be no problem if you bend the flanges with a tool like the one 

in your picture or a simple stick with a slot cut in it.  On the 

other hand, the hole tolerance must be very tight if you use press 

dies to make the flanges.



Rather than cutting off a 2x4 piece of aluminum for experimenting, I 

would recommend trying to make some specific parts like perhaps 

elevator ribs and cut the exact part needed for each attempt.



Good luck and welcome to the club.



Paul

XL fuselage

do not archive

At 01:15 PM 5/8/2007, you wrote:

 	  Quote: 	
		  Hi guys,  I promise I won't load this list up with every little move

but today I ordered my first sheet of Aluminum (4' x 8' x .025") and

built a hole flanging tool.  The tool cost about $3.50.  I have

nothing to try it on, but here it is.



   I am  scratch building but might buy a part or two if the going

gets too tough. I plan to cut 2' x 4' off the sheet I just ordered to

use for practice.



Question,  How critical are the diameters of the lightening holes?

I can buy hole saws that are quite close in size but not exact.

Morse offers saws in 1/8" increments.     Thanks,



Jerry Hey

STOL 701

- The Matronics Zenith-List Email Forum -

Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:

http://www.matronics.com/Navigator?Zenith-List

bill_dom(at)yahoo.com
Guest

Posted: Wed May 09, 2007 4:28 am Post subject: Day one

Can you post the link to the Morse site? Thanks

  

  William Dominguez

  Zodiac 601XL Plans

  Miami, Florida



Jerry Hey <jerryhey(at)earthlink.net> wrote:[quote]  --> Zenith-List message posted by: Jerry Hey 



Looking further at the Morse site, I found they had metric hole saws  

in all the sizes needed.  I ordered 65mm, 95mm and 114mm.  Jerry

  [b]

- The Matronics Zenith-List Email Forum -

Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:

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JerryHey

Joined: 05 May 2007
Posts: 30

Posted: Wed May 09, 2007 4:40 am Post subject: Day one

Sure.  www.mkmorse.com     



On May 9, 2007, at 8:27 AM, William Dominguez wrote:

 	  Quote: 	
		  Can you post the link to the Morse site? Thanks

  

  William Dominguez

  Zodiac 601XL Plans

  Miami, Florida



Jerry Hey <jerryhey(at)earthlink.net (jerryhey(at)earthlink.net)> wrote: 	  Quote: 	
		    --> Zenith-List message posted by: Jerry Hey 



Looking further at the Morse site, I found they had metric hole saws  

in all the sizes needed.  I ordered 65mm, 95mm and 114mm.  Jerry

  

href="http://www.matronics.com/Navigator?Zenith-List">http://www.matronics.com/Navigator?Zenith-List

href="http://forums.matronics.com">http://forums.matronics.com



	
	




 [quote][b]

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bill_dom(at)yahoo.com
Guest

Posted: Wed May 09, 2007 5:15 am Post subject: Day one

Thanks.

  

  do not archive



Jerry Hey <jerryhey(at)earthlink.net> wrote:[quote]  Sure.  www.mkmorse.com     



On May 9, 2007, at 8:27 AM, William Dominguez wrote:

[quote]Can you post the link to the Morse site? Thanks

  

  William Dominguez

  Zodiac 601XL Plans

  Miami, Florida



Jerry Hey <jerryhey(at)earthlink.net (jerryhey(at)earthlink.net)> wrote:[quote][b]

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n4546v(at)mindspring.com
Guest

Posted: Wed May 09, 2007 7:53 am Post subject: Day one

Hey Jerry:

     Care to tell us the price of  such nice hole saws?  If you use flanging dies, hole diameter is not  critical, but what is critical is after you cut the holes with any tool, be sure  to sand around the inside of the hole until it is smooth enough to run your  finger around inside and feel NOTHING.  If you leave ANY nick etc., the  flange can easily crack while forming.  How do I know this?  >From  "experience".  And a fly-cutter works fine with the right setup in a drill  press.

  

 Regards,

  

 Randy L. Thwing, Las Vegas  do not  archive

  

  

  

  

 I ordered 65mm, 95mm and 114mm. Jerry

   [quote][b]

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