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carlossa52(at)gmail.com
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 Posted: Tue Mar 11, 2014 3:55 pm Post subject: weird hole |
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Hello,
Does anyone know how to drill a hole as indicated in this pdf?
http://switches-connectors-custom.cwind.com/Asset/GRB213B03BB.pdf
Is there a special tool? Just curious...
Thanks
Carlos
CH601-HD, plans
inspection this summer
[quote][b]
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craig(at)craigandjean.com
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| Posted: Tue Mar 11, 2014 5:15 pm Post subject: weird hole |
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There are specialized chassis punches but they cost a fortune. When faced with similar "flat sided" holes I've drilled the round hole and then backed it with a plate with a rectangular hole whose smaller dimension is the distance between the two flats and the longer dimension being the diameter of the round hole. You can also just mark the dimension on your panel and cut up to the edge with a series of smaller holes and some work with a fine file. But this is tedious and error-prone.
I find the standard bat-handled toggle switches with the small satellite hole for the tooth on the anti-rotation washer to be easier.
-- Craig
On Tue, Mar 11, 2014 at 4:53 PM, Carlos Sa <carlossa52(at)gmail.com (carlossa52(at)gmail.com)> wrote:
[quote] Hello,
Does anyone know how to drill a hole as indicated in this pdf?
http://switches-connectors-custom.cwind.com/Asset/GRB213B03BB.pdf
Is there a special tool? Just curious...
Thanks
Carlos
CH601-HD, plans
inspection this summer
| Quote: |
arget="_blank">http://www.matronics.com/Navigator?Zenith-List
tp://forums.matronics.com
_blank">http://www.matronics.com/contribution
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[b]
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bryanmmartin
Joined: 10 Jan 2006
Posts: 1018
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| Posted: Tue Mar 11, 2014 5:15 pm Post subject: weird hole |
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Large scale manufacturers would use a special hole punch or CNC machine for this but I would just use a drill with the same diameter as the distance across the flats and then file it to size with a round file.
--
Bryan Martin
N61BM, CH 601 XL,
RAM Subaru, Stratus re-drive.
On Mar 11, 2014, at 7:53 PM, Carlos Sa <carlossa52(at)gmail.com (carlossa52(at)gmail.com)> wrote:
[quote]Hello,
Does anyone know how to drill a hole as indicated in this pdf?
http://switches-connectors-custom.cwind.com/Asset/GRB213B03BB.pdf
Is there a special tool? Just curious...
Thanks
Carlos
CH601-HD, plans
inspection this summer
[b]
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_________________
--
Bryan Martin
N61BM, CH 601 XL, Stratus Subaru.
do not archive. |
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psm(at)att.net
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| Posted: Tue Mar 11, 2014 10:35 pm Post subject: weird hole |
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psm(at)att.net
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| Posted: Wed Mar 12, 2014 4:01 am Post subject: weird hole |
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Hi Carlos,
It seems I am having computer problems of some sort. I sent a message
describing how to make any hole you want in sheet aluminum and the
computer/net seems to have eaten all the content. I also lost my "Send"
file copy. Gremlins!
Anyway the short version for any hole:
1. Mark the hole outline with an ultra-fine marker. A pattern can help
with this.
2. Drill the center or possibly a couple of corners inside the marked
outline.
3. (For bigger holes) Cut close to outline with snips.
4. Finish cutting with a Dremel tool with "Christmas Tree" shaped high
speed cutter. Use the point area for fine adjustments and the wider
areas for quicker material removal.
5. Use hand file to finish hole - remove sharp edges and prevent loss
of blood.
Good luck,
Paul
XL - finished flight test and signed off.
On 3/11/2014 4:53 PM, Carlos Sa wrote:
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BARRY CHECK 6
Joined: 15 Mar 2011
Posts: 738
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| Posted: Wed Mar 12, 2014 5:59 am Post subject: weird hole |
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Carlos:
Drill a 12.2 mm hole.
Or spend $100 and buy a punch... I would just drill a 12.2 mm hole and be done with it.
BUT! If YOU try to drill the hole I'd bet dolars to donuts that it will mess up the panel. SOOooooo, drill a 1/4" hole and then REAM it out to fit. Use a TAPERED REAMER. You will have better control and NO chance of the drill and bit getting away from you. Also, use a vacuum cleaner as you work to pick up the metal chips.
Barry
On Tue, Mar 11, 2014 at 7:53 PM, Carlos Sa <carlossa52(at)gmail.com (carlossa52(at)gmail.com)> wrote:
[quote]Hello,
Does anyone know how to drill a hole as indicated in this pdf?
http://switches-connectors-custom.cwind.com/Asset/GRB213B03BB.pdf
Is there a special tool? Just curious...
Thanks
Carlos
CH601-HD, plans
inspection this summer
| Quote: |
arget="_blank">http://www.matronics.com/Navigator?Zenith-List
tp://forums.matronics.com
_blank">http://www.matronics.com/contribution
|
[b]
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malcolmhunt(at)mha1.fsbus
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| Posted: Wed Mar 12, 2014 9:40 am Post subject: weird hole |
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Carlos
Can I just add to Paul’s excellent advice. As a plans builder you will have a shed load of off-cuts and scrap so you drill three holes.
The first is in a piece of scrap and will be probably rubbish; the second will also be in a piece of scrap and will be pretty good; the third will be on your aircraft and be like the dogs dangly bits – perfect.
My two pennies worth but best of luck
Malcolm Hunt
CH601XL plans builder in England
From: owner-zenith-list-server(at)matronics.com [mailto:owner-zenith-list-server(at)matronics.com] On Behalf Of Carlos Sa
Sent: 11 March 2014 23:54
To: zenith-list(at)matronics.com
Subject: weird hole
Hello,
Does anyone know how to drill a hole as indicated in this pdf?
http://switches-connectors-custom.cwind.com/Asset/GRB213B03BB.pdf
Is there a special tool? Just curious...
Thanks
Carlos
CH601-HD, plans
inspection this summer
| Quote: | | http://www.matronics.com/Navigator?Zenith-List |
01234567
__________ Information from ESET Smart Security, version of virus signature database 9530 (20140311) __________
The message was checked by ESET Smart Security.
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BARRY CHECK 6
Joined: 15 Mar 2011
Posts: 738
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| Posted: Wed Mar 12, 2014 11:44 am Post subject: weird hole |
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You guys are joking! Right?
You are going to spend over an hour making a hole! One stinking HOLE!
And who knows the quality of the workmanship in making that hole. The better the workmanship the more time is going to be spent.
I like dogs and I like cats and there are many ways to skin a cat but to be bull dog stubborn on a simple hole you got to be kidding.
BUY a DIFFERENT switch.
But, wait, if there are more than one hole, is there enough holes to justify buying a punch?
Barry
On Wed, Mar 12, 2014 at 1:40 PM, Malcolm Hunt <malcolmhunt(at)mha1.fsbusiness.co.uk (malcolmhunt(at)mha1.fsbusiness.co.uk)> wrote:
[quote]
Carlos
Can I just add to Paul’s excellent advice. As a plans builder you will have a shed load of off-cuts and scrap so you drill three holes.
The first is in a piece of scrap and will be probably rubbish; the second will also be in a piece of scrap and will be pretty good; the third will be on your aircraft and be like the dogs dangly bits – perfect.
My two pennies worth but best of luck
Malcolm Hunt
CH601XL plans builder in England
From: owner-zenith-list-server(at)matronics.com (owner-zenith-list-server(at)matronics.com) [mailto:owner-zenith-list-server(at)matronics.com (owner-zenith-list-server(at)matronics.com)] On Behalf Of Carlos Sa
Sent: 11 March 2014 23:54
To: zenith-list(at)matronics.com (zenith-list(at)matronics.com)
Subject: weird hole
Hello,
Does anyone know how to drill a hole as indicated in this pdf?
http://switches-connectors-custom.cwind.com/Asset/GRB213B03BB.pdf
Is there a special tool? Just curious...
Thanks
Carlos
CH601-HD, plans
inspection this summer
0 12345 67
__________ Information from ESET Smart Security, version of virus signature database 9530 (20140311) __________
The message was checked by ESET Smart Security.
="http://www.matronics.com/Navigator?Zenith-List" target="_blank">http://www.matronics.com/Navigator?Zenith-List tp://forums.matronics.com _blank">http://www.matronics.com/contribution
[b]
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malcolmhunt(at)mha1.fsbus
Guest
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| Posted: Wed Mar 12, 2014 12:28 pm Post subject: weird hole |
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Thanks Barry but as a plans builder I learned early on that every single hole has to be treated with respect as it is too easy to drill it in the wrong place or end up forming an aperture which is un-usable. More scrap!!!
I think one of the benefits of the list is the breadth of opinion which has helped me enormously over the past few years.
Kind regards
Malcolm Hunt
From: owner-zenith-list-server(at)matronics.com [mailto:owner-zenith-list-server(at)matronics.com] On Behalf Of FLYaDIVE
Sent: 12 March 2014 19:44
To: zenith-list(at)matronics.com
Subject: Re: weird hole
You guys are joking! Right?
You are going to spend over an hour making a hole! One stinking HOLE!
And who knows the quality of the workmanship in making that hole. The better the workmanship the more time is going to be spent.
I like dogs and I like cats and there are many ways to skin a cat but to be bull dog stubborn on a simple hole you got to be kidding.
BUY a DIFFERENT switch.
But, wait, if there are more than one hole, is there enough holes to justify buying a punch?
Barry
On Wed, Mar 12, 2014 at 1:40 PM, Malcolm Hunt <malcolmhunt(at)mha1.fsbusiness.co.uk (malcolmhunt(at)mha1.fsbusiness.co.uk)> wrote:
Carlos
Can I just add to Paul’s excellent advice. As a plans builder you will have a shed load of off-cuts and scrap so you drill three holes.
The first is in a piece of scrap and will be probably rubbish; the second will also be in a piece of scrap and will be pretty good; the third will be on your aircraft and be like the dogs dangly bits – perfect.
My two pennies worth but best of luck
Malcolm Hunt
CH601XL plans builder in England
From: owner-zenith-list-server(at)matronics.com (owner-zenith-list-server(at)matronics.com) [mailto:owner-zenith-list-server(at)matronics.com (owner-zenith-list-server(at)matronics.com)] On Behalf Of Carlos Sa
Sent: 11 March 2014 23:54
To: zenith-list(at)matronics.com (zenith-list(at)matronics.com)
Subject: weird hole
Hello,
Does anyone know how to drill a hole as indicated in this pdf?
http://switches-connectors-custom.cwind.com/Asset/GRB213B03BB.pdf
Is there a special tool? Just curious...
Thanks
Carlos
CH601-HD, plans
inspection this summer
__________ Information from ESET Smart Security, version of virus signature database 9530 (20140311) __________
The message was checked by ESET Smart Security.
="http://www.matronics.com/Navigator?Zenith-List" target="_blank">http://www.matronics.com/Navigator?Zenith-List tp://forums.matronics.com _blank">http://www.matronics.com/contribution
01234567890123
__________ Information from ESET Smart Security, version of virus signature database 9533 (20140312) __________
The message was checked by ESET Smart Security.
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ggower_99(at)yahoo.com
Guest
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| Posted: Wed Mar 12, 2014 12:31 pm Post subject: weird hole |
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Looking closely to the pdf page...
I think that the hole to install the switch is a normal round hole, like any other switch with a nut...
Looks that the plastic parts of the switch are the ones that have that rectangular form...
Gary.
On Wednesday, March 12, 2014 1:58 PM, FLYaDIVE <flyadive(at)gmail.com> wrote:
You guys are joking! Right?
You are going to spend over an hour making a hole! One stinking HOLE!
And who knows the quality of the workmanship in making that hole. The better the workmanship the more time is going to be spent.
I like dogs and I like cats and there are many ways to skin a cat but to be bull dog stubborn on a simple hole you got to be kidding.
BUY a DIFFERENT switch.
But, wait, if there are more than one hole, is there enough holes to justify buying a punch?
Barry
On Wed, Mar 12, 2014 at 1:40 PM, Malcolm Hunt <malcolmhunt(at)mha1.fsbusiness.co.uk (malcolmhunt(at)mha1.fsbusiness.co.uk)> wrote:
| Quote: | Carlos
Can I just add to Paul’s excellent advice. As a plans builder you will have a shed load of off-cuts and scrap so you drill three holes.
The first is in a piece of scrap and will be probably rubbish; the second will also be in a piece of scrap and will be pretty good; the third will be on your aircraft and be like the dogs dangly bits – perfect.
My two pennies worth but best of luck
Malcolm Hunt
CH601XL plans builder in England
From: owner-zenith-list-server(at)matronics.com (owner-zenith-list-server(at)matronics.com) [mailto:owner-zenith-list-server(at)matronics.com (owner-zenith-list-server(at)matronics.com)] On Behalf Of Carlos Sa
Sent: 11 March 2014 23:54
To: zenith-list(at)matronics.com (zenith-list(at)matronics.com)
Subject: Zenith-List: weird hole
Hello,
Does anyone know how to drill a hole as indicated in this pdf?
http://switches-connectors-custom.cwind.com/Asset/GRB213B03BB.pdf
Is there a special tool? Just curious...
Thanks
Carlos
CH601-HD, plans
inspection this summer
0 12345 67
__________ Information from ESET Smart Security, version of virus signature database 9530 (20140311) __________
The message was checked by ESET Smart Security.
[url=] ="http://www.matronics.com/Navigator?Zenith-List" target="_blank">http://www.matronics.com/Navigator?Zenith-List[/url] tp://forums.matronics.com _blank">http://www.matronics.com/contribution
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8
[quote][b]
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s.clive.richards(at)homec
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| Posted: Wed Mar 12, 2014 1:44 pm Post subject: weird hole |
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Gary If you look at your PDF top RHS you will see it is not a round hole as there are flats to stop switch rotating in panel If it is a one off drill 11 mm hole and file top & bottom of hole out to 12.2 mm with a small half round file to fit switch.
Clive
[quote] ---
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ggower_99(at)yahoo.com
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| Posted: Wed Mar 12, 2014 3:09 pm Post subject: weird hole |
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Yes, I have installed lots of this type of switches... Make it round.
Just apply a tiny drop of paint (the red nail paint you use in the bolts and nuts will work) betwen the switch and the instrument panel (or a drop of contact cement, if you have one opened and not dried), before tightening the nut and the switch will not move... I am shure you will never try to twist the switch to turn it on...
Same happens with the ones that have a "tonge" in the professionaly made hole and the switch has a groove...
This is designed to resist abuse from some Fred Flitstone type of users... 
We pilots are lot more carefull when switching in our pride and joy...
Gary
On Wednesday, March 12, 2014 4:00 PM, Clive Richards <s.clive.richards(at)homecall.co.uk> wrote:
Gary If you look at your PDF top RHS you will see it is not a round hole as there are flats to stop switch rotating in panel If it is a one off drill 11 mm hole and file top & bottom of hole out to 12.2 mm with a small half round file to fit switch.
Clive
[quote] ---
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psm(at)att.net
Guest
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| Posted: Wed Mar 12, 2014 3:21 pm Post subject: weird hole |
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Gary,
First, I think your estimate of an hour to make this hole properly is off by about 55 minutes. Once you get the process down this simple little hole with the flats might take as much as 5 minutes.
Second, If you are not willing to take a few minutes to do this little job right they perhaps you would be better advised to buy a spam can than to build your own plane.
Paul
Camas, WA
On 3/12/2014 4:07 PM, Gary Gower wrote:
[quote] Yes, I have installed lots of this type of switches... Make it round.
Just apply a tiny drop of paint (the red nail paint you use in the bolts and nuts will work) betwen the switch and the instrument panel (or a drop of contact cement, if you have one opened and not dried), before tightening the nut and the switch will not move... I am shure you will never try to twist the switch to turn it on... Â
Same happens with the ones that have a "tonge" in the professionaly made hole and the switch has a groove...Â
This is designed to resist abuse from some Fred Flitstone type of users... Â
We pilots are lot more carefull when switching in our pride and joy...
Gary
[b]
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n801bh(at)netzero.com
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sabrina
Joined: 15 Jun 2009
Posts: 170
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| Posted: Wed Mar 12, 2014 10:47 pm Post subject: Re: weird hole |
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One problem is that DC is harder to switch than AC. Your switch is AC rated.
I know you are worried about hitting your head on a toggle switch, but I would be more concerned about an AC-only rated switch causing a problem in flight that could be much worse than that...
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carlossa52(at)gmail.com
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| Posted: Thu Mar 13, 2014 4:25 am Post subject: weird hole |
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Hello, Sabrina
That was just a sample I had handy to show the diagram.
There are plenty of rocker switches with the proper characteristics that I can choose from.
Regards
Carlos
On 13 March 2014 02:47, sabrina <chicago2paris(at)msn.com (chicago2paris(at)msn.com)> wrote:
[quote]--> Zenith-List message posted by: "sabrina" <chicago2paris(at)msn.com (chicago2paris(at)msn.com)>
One problem is that DC is harder to switch than AC. Your switch is AC rated.
I know you are worried about hitting your head on a toggle switch, but I would be more concerned about an AC-only rated switch causing a problem in flight that could be much worse than that...
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p=420258#420258
Attachments:
http://forums.matronics.com//files/dc_rated_880.jpg
http://forums.matronics.com//files/ac_rated_105.jpg
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