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follow up question about 601 rear spar hole

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w8n2bup

Joined: 09 Apr 2008
Posts: 20
Location: Kansas City Area

Posted: Fri Apr 11, 2008 4:58 pm Post subject: follow up question about 601 rear spar hole

Thanks to all of you who made suggestions regarding the 1 1/2 hole in the rear spar channel for the aileron rod. I think I will move it up to the edge of the curve,make slightly smaller and probably add the doubler. I read a comment about being careful on cuts, to not leave any tiny "cracks" on edges as these could get larger over time. I don't a "fly cutter", as Zenith suggests, but have found it very useful to use my roto-zip tool to cut many parts, including holes and then smoothing out with the curve side of my file. These cuts appear to be quite smooth to me though not as if they were cut with a precision tool, as some tiny marks are left by the file. Does anyone have experience in this area? Is a filed piece that has no visible lines going out quite sufficient or am I being overly concerned about smoothness? Thanks again, John

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Tim Juhl

Joined: 21 Mar 2006
Posts: 488
Location: "Thumb" of Michigan

Posted: Sat Apr 12, 2008 8:55 am Post subject: Re: follow up question about 601 rear spar hole

A little waviness in the edge is a cosmetic issue.  You just don't want any nicks that could serve as the starting point for cracks.  Even the edges of holes cut with a flycutter require some treatment to smooth them out.



I would like to add that a flycutter is a very useful tool.  I added a couple of additional inspection holes to each wing and of course had to cut the hole for the fuel tank filler. There is also the top hole for the nose gear support which needs to be carefully sized. The flycutter does a real nice job (I turn it by hand) and a Olfa knife (P800) is a great way to cut straight lines.  With a project like the XL having the right tools can make a big difference both in time and quality.



Tim



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Posted: Sat Apr 12, 2008 10:00 am Post subject: follow up question about 601 rear spar hole

John;



The basic desirable finish is one where the cut edge is a continuous smooth sheared surface. Any scratches or tool marks should be parallel to the edge cut.



Just be sure that when you debur the edge made with the router that you do not leave scratches running across the edge.



w8n2bup <johnrich(at)everestkc.net> wrote:[quote] --> Zenith-List message posted by: "w8n2bup" 



Thanks to all of you who made suggestions regarding the 1 1/2 hole in the rear spar channel for the aileron rod. I think I will move it up to the edge of the curve,make slightly smaller and probably add the doubler. I read a comment about being careful on cuts, to not leave any tiny "cracks" on edges as these could get larger over time. I don't a "fly cutter", as Zenith suggests, but have found it very useful to use my roto-zip  [quote][b]

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