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Making those funny holes

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craig(at)craigandjean.com
Guest

Posted: Fri May 26, 2006 9:22 am Post subject: Making those funny holes

There is plenty of information in the archives on drilling the holes for

toggle switches and their anti-rotation washers. I have two other items

going into my control panel that pose different problems. First my magneto

switch (like a toggle switch) has a channel machined along the threaded

shaft. But it was not supplied with a matching anti-rotation washer. The

diameter of the shaft is 7/8th of an inch. Second my power outlet (cigarette

lighter socket) needs a 1 1/8th inch hole but has flats on each side to keep

it from rotating. The flats are about 3/8th of an inch wide.



How do I cut the holes to match these parts?



-- Craig

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deej(at)deej.net
Guest

Posted: Fri May 26, 2006 9:39 am Post subject: Making those funny holes

Craig Payne wrote:

 	  Quote: 	
		   Second my power outlet (cigarette

 lighter socket) needs a 1 1/8th inch hole but has flats on each side to keep

 it from rotating. The flats are about 3/8th of an inch wide.

   

    I just cut a round hole for my cigarette lighter socket.  It is 
	


round - who cares

what orientation it is in?  *grin*



    Having said that, it has not turned in the 2 years it has been 

installed and flying.



-Dj



do not archive



-- 

Dj Merrill - N1JOV

Glastar Sportsman 2+2 Builder #7118

http://econ.duke.edu/~deej/sportsman/



"Many things that are unexplainable happen during the construction of an 

airplane."  --Dave Prizio, 30 Aug 2005

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craig(at)craigandjean.com
Guest

Posted: Fri May 26, 2006 10:19 am Post subject: Making those funny holes

 	  Quote: 	
		  > It is round - who cares what orientation it is in?  *grin*


	


Sadly mine is round but labeled, has a captive rubber cap and accepts a

optional locking plug which inserts in one orientation to lock. You twist it

to remove.



-- Craig

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rv9jim(at)juno.com
Guest

Posted: Fri May 26, 2006 12:32 pm Post subject: Making those funny holes

Drill the smaller diameter and then get out the file and make it fit.  

It the hard way but it works



Jim

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larry(at)macsmachine.com
Guest

Posted: Fri May 26, 2006 12:32 pm Post subject: Making those funny holes

Craig,

I've made special holes in a separate steel plate, filed to the lines 

needed and clamped the plate in front and cut

a repeat copy of the holes where they were needed.  Takes a little time, 

but not that hard with a good set of small

files and drills.



Larry McFarland - 601HDS

do not archive



Craig Payne wrote:



 	  Quote: 	
		  



There is plenty of information in the archives on drilling the holes for

toggle switches and their anti-rotation washers. I have two other items

going into my control panel that pose different problems. First my magneto

switch (like a toggle switch) has a channel machined along the threaded

shaft. But it was not supplied with a matching anti-rotation washer. The

diameter of the shaft is 7/8th of an inch. Second my power outlet (cigarette

lighter socket) needs a 1 1/8th inch hole but has flats on each side to keep

it from rotating. The flats are about 3/8th of an inch wide.



How do I cut the holes to match these parts?



-- Craig

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craig(at)craigandjean.com
Guest

Posted: Fri May 26, 2006 1:07 pm Post subject: Making those funny holes

 	  Quote: 	
		  > not that hard with a good set of small files and drills


	


Given the small number that I have to make I guess that is what I will have

to do. I was just looking for a trick. Good idea to make a steel master

first. That reduces the chance of my screwing up the actual panel. For the

magneto switch I may isolate the problem by just making my own anti-rotation

washer, a scaled-up version of the ones that come with a toggle switch. The

same idea could be used with the power outlet.



-- Craig

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mprather(at)spro.net
Guest

Posted: Fri May 26, 2006 1:43 pm Post subject: Making those funny holes

Is the panel mounted in the plane?  If not, how about waterjet?



Course, as someone else suggested, trace the shape of the cutout carfully,

drill a hole smaller than required, and then use files to open up the hole

to the tracing.

Regards,



Matt-



 	  Quote: 	
		   

 <craig(at)craigandjean.com>



 There is plenty of information in the archives on drilling the holes for

 toggle switches and their anti-rotation washers. I have two other items

 going into my control panel that pose different problems. First my

 magneto switch (like a toggle switch) has a channel machined along the

 threaded shaft. But it was not supplied with a matching anti-rotation

 washer. The diameter of the shaft is 7/8th of an inch. Second my power

 outlet (cigarette lighter socket) needs a 1 1/8th inch hole but has

 flats on each side to keep it from rotating. The flats are about 3/8th

 of an inch wide.



 How do I cut the holes to match these parts?



 -- Craig

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jm(at)10squaredcorp.com
Guest

Posted: Fri May 26, 2006 5:20 pm Post subject: Making those funny holes

Someone installed a VOR head in my Stinson before I bought it and it 

looks like the cutout was done by a six year old. I'm guessing it was 

done with a file. Perhaps there are talented file users out there, 

but let me throw out this suggestion: create a template for the curve 

you need and attach a guide to a high speed grinding tool with a fine 

stone wheel. Similar to technique used with a router.



Cheers,



Jim



On Friday 26 May 2006 21:39, Matt Prather wrote:

 	  Quote: 	
		   

 <mprather(at)spro.net>



 Is the panel mounted in the plane?  If not, how about waterjet?



 Course, as someone else suggested, trace the shape of the cutout

 carfully, drill a hole smaller than required, and then use files to

 open up the hole to the tracing.

 Regards,



 Matt-



 > 

 > <craig(at)craigandjean.com>

 >

 > There is plenty of information in the archives on drilling the

 > holes for toggle switches and their anti-rotation washers. I have

 > two other items going into my control panel that pose different

 > problems. First my magneto switch (like a toggle switch) has a

 > channel machined along the threaded shaft. But it was not

 > supplied with a matching anti-rotation washer. The diameter of

 > the shaft is 7/8th of an inch. Second my power outlet (cigarette

 > lighter socket) needs a 1 1/8th inch hole but has flats on each

 > side to keep it from rotating. The flats are about 3/8th of an

 > inch wide.

 >

 > How do I cut the holes to match these parts?

 >

 > -- Craig

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