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Inspection covers

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larry(at)macsmachine.com
Guest

Posted: Mon Jan 15, 2007 7:49 am Post subject: Inspection covers

Hi John,

I like the round ones for wings and fuselage sides.

I located inspection holes each side of the fuselage just about 10 

inches ahead of the bulkhead and above where cables exit.

These holes were cut by hand with a fly-cutter.  The cutting point needs 

to be flat-side out to get a flush square edge. The

center holes are pre-drilled, 1/16 pilot, then a sharp drill the same 

size as the center-guide drill in your fly-cutter. Use light

pressure for both drilling and fly-cutting by hand.  Do a sample piece 

first to get the feel for the process.

It takes only about 10 minutes to cut a nice hole in the fuselage by 

hand,  about 1 second to mess one up using

a drill, so do the fly-cutting manually in the same way that you'd use a 

compass.

See links,

http://www.macsmachine.com/images/largeassembly2/full/inspectail.gif

http://www.macsmachine.com/images/largeassembly2/full/innertail.gif

http://www.macsmachine.com/images/rudder/full/rudelev.gif



I cut 5-inch diameter disks from .040 6061-T6, spun them on a lathe to 

reduce a 1/4 inch edge to .038 so that they

stay centered inside the 4-1/2 inch diameter inspection hole. I imagine 

three or four recess head pop rivets

could have been used to do the same centering action.

 

The spiders are just a 5-3/4 inch .040 6061-T6 disk that have been cut 

to an X with legs that are 7/8-inch wide,

extending to within 7/8-inch of the center hole.   The spider is bent 

1/2 inch in from the tips, 3/4 inch out from the

center so the ends are flat and the center of the spider is exactly 1/2 

inch above the disk it sets on.



8-32 rivnuts and 1-inch long recess head stainless screws secure the two 

pieces. These are easily removed and

replaced by simply loosening and tightening the screw and there is no 

noticeable deformation nor do the screws need to be

tightened more than snug. See link.

http://www.macsmachine.com/images/wing/inspectionpanels/full/spiders.jpg



On the under wing disks, I added a screw to the lead edge of the disk to 

grab a j-nut on the spider and a hole in the skin

which keeps the edge down tight and unaffected by the deflected air up 

front.  Not needed at the fuselage though.

See links.

http://www.macsmachine.com/images/wing/inspectionpanels/full/accessspydersafety.gif 



http://www.macsmachine.com/images/wing/inspectionpanels/full/accessplate2.gif 



http://www.macsmachine.com/images/wing/inspectionpanels/full/accessplate3.gif 



http://www.macsmachine.com/images/paint/full/601ezclosefrtrt.gif



These inspection covers work quite well and will not give you any 

trouble in the air or otherwise.

Hope this is useful.



Larry McFarland - 601HDS at www.macsmachine.com

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Float Flyr

Joined: 19 Jul 2006
Posts: 2704
Location: Campbellton, Newfoundland

Posted: Mon Jan 15, 2007 9:21 am Post subject: Inspection covers

A truly beautiful job on your plane.  



One question though ... For what radio is the longer antenna on the back of

your plane used??



Noel



[quote] --

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_________________
Noel Loveys
Kitfox III-A
Aerocet 1100 Floats

ter_turn(at)yahoo.com
Guest

Posted: Mon Jan 15, 2007 11:30 am Post subject: Inspection covers

Larry, you da man!

   

  Terry Turnquist

  601XL-Plans

  St. Peters, MO



LarryMcFarland <larry(at)macsmachine.com> wrote:

  [quote]--> Zenith-List message posted by: LarryMcFarland 



Hi John,

I like the round ones for wings and fuselage sides.

I located inspection holes each side of the fuselage just about 10 

inches ahead of the bulkhead and above where cables exit.

These holes were cut by hand with a fly-cutter. The cutting point needs 

to be flat-side out to get a flush square edge. The

center holes are pre-drilled, 1/16 pilot, then a sharp drill the same 

size as the center-guide drill in your fly-cutter. Use light

pressure for both drilling and fly-cutting by hand. Do a sample piece 

first to get the feel for the process.

It takes only  about 10 minutes to cut a nice hole in the fuselage by 

hand, about 1 second to mess one up using

a drill, so do the fly-cutting manually in the same way that you'd use a 

compass.

See links,

http://www.macsmachine.com/images/largeassembly2/full/inspectail.gif

http://www.macsmachine.com/images/largeassembly2/full/innertail.gif

http://www.macsmachine.com/images/rudder/full/rudelev.gif



I cut 5-inch diameter disks from .040 6061-T6, spun them on a lathe to 

reduce a 1/4 inch edge to .038 so that they

stay centered inside the 4-1/2 inch diameter inspection hole. I imagine 

three or four recess head pop rivets

could have been used to do the same centering action.



The spiders are just a 5-3/4 inch .040 6061-T6 disk that have been cut 

to an X with legs that are 7/8-inch wide,

extending to within 7/8-inch of the center hole. The spider is bent 

1/2 inch in from the tips, 3/4 inch out from the

center so the ends are flat  and the center of the spider is exactly 1/2 

inch above the disk it sets on.



8-32 rivnuts and 1-inch long recess head stainless screws secure the two 

pieces. These are easily removed and

replaced by simply loosening and tightening the screw and there is no 

noticeable deformation nor do the screws need to be

tightened more than snug. See link.

http://www.macsmachine.com/images/wing/inspectionpanels/full/spiders.jpg



On the under wing disks, I added a screw to the lead edge of the disk to 

grab a j-nut on the spider and a hole in the skin

which keeps the edge down tight and unaffected by the deflected air up 

front. Not needed at the fuselage though.

See links.

http://www.macsmachine.com/images/wing/inspectionpanels/full/accessspydersafety.gif 



http://www.macsmachine.com/images/wing/inspectionpanels/full/accessplate2.gif 



http://www.macsmachine.com/images/wing/inspectionpanels/full/accessplate3.gif 	     Looking for earth-friendly autos? 

 Browse Top Cars by "Green Rating" at Yahoo! Autos' Green Center.   [quote][b]

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larry(at)macsmachine.com
Guest

Posted: Mon Jan 15, 2007 12:57 pm Post subject: Inspection covers

Hi Noel,

Thank you,  the rear antenna is for the ELT and the forward one is for 

the ICom AC200.



Larry McFarland 601HDS at www.macsmachine.com

do not archive

Noel Loveys wrote:

 	  Quote: 	
		   



 A truly beautiful job on your plane.  



 One question though ... For what radio is the longer antenna on the back of

 your plane used??



 Noel

- 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

JohnDRead(at)aol.com
Guest

Posted: Mon Jan 15, 2007 10:34 pm Post subject: Inspection covers

Hello List:

                 Thanks  for all the great suggestions for inspection holes and ding removal.

  

 Regards, John Read

  

 do not archive

  [quote][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:

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

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