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February 24th, 2008
More Countersinking on the Spar
After starting to countersink everything with the #21 countersink, I started to run into problems where the bit would chatter and bounce around in the holes. It left a buggered up hole so I quite and started to look around the forums. I found out this is a common problem and I should have researched it first before starting. Anyway see my last log entry for more details. Once I switched back to the #30 I was able to clean up the messed up holes and they look fine.
Now back to the alignment tool I made in my previous log entry. It is not pretty but it works like a champ. Using a #30 countersink and the jig makes the holes come out perfect. The only reason I used this method instead of first riveting the nutplates on is (1) I wanted to debur the holes and (2) with the nut plate I would get aluminum shavings and chips falling down in the hole between the nutplate and spar. So this method saved me from having to dig them out.
I had to cut up my original tool so it would fit the angled nutplates near the root of the spar. You can see where I cut it off to fit.
Another angle that showing the opposite direction.
People say that you might not need to debur the holes because of the knife edge it creates. Look closely at the picture below and you can see the bur that get's left behind. A quick light handed pass with the debur tool gets rid of these.
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