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Old 01-15-2019, 11:39 PM
wjb's Avatar
wjb wjb is offline
Join Date: Nov 2012
Location: Half Moon Bay, CA
Posts: 1,121

I've been hand drilling the countersinks in my cowl using some carbide-burr countersink bits with great results. Go slow, and check often. All have come out just right.
Bill Bencze
N430WB RV-7 @KHAF, Flying 100+ hrs
VAF 2021 donation happily made
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Old 01-16-2019, 12:23 PM
bk1bennett's Avatar
bk1bennett bk1bennett is offline
Join Date: Nov 2015
Location: Sachse, TX
Posts: 81

I used a drill press and my calibrated eyeball.
Latest Donation Dates: 06 August 2020 & Dec 2020
RV-14A Empennage Kit #140396
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Old 01-16-2019, 06:05 PM
RV10Pilot RV10Pilot is offline
Join Date: Jan 2005
Location: Medford, NJ USA
Posts: 475

How about something like this
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Old 01-16-2019, 06:34 PM
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scard scard is offline
Join Date: Jun 2005
Location: Cedar Park, TX
Posts: 3,368

Yep. I call it kamikaze counter sinking or dimpling. Free hand can liberate you from the cage . Just be darn sure you can meet your quality assurance expectations before ruining a part. The other such operation is a dimple die in the rivet gun and it's companion in a backing buck. Do you feel lucky? <smily face fully implied!>

Once you get over the pressures, angles, and all the ways this could go wrong, you'll be moving right along without so much jig analysis. I know a Boeing production engineer would be squirming in his seat, but we aren't build a space shuttle here.
Scott Card
CQ Headset by Card Machine Works
CMW E-Lift
RV-9A N4822C flying 2200+hrs. / Cedar Park, TX
RV8 Building - fuselage / showplanes canopy (Done!)
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Old 01-16-2019, 08:13 PM
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ColoCardinal ColoCardinal is offline
Join Date: May 2010
Location: Morrison, CO
Posts: 372
Default countersink

. . or you could replace them with an internal stop:
Carl - - Morrison, CO
Airworthiness cert issued 12/24
best X-mas present I could have hoped for!
paid 'til 10-19
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Old 01-19-2019, 03:56 PM
RonS RonS is offline
Join Date: Nov 2018
Location: Roswell, GA
Posts: 32

Hit this same issue last week. I picked up a paint cutter arbor from Spruce which is threaded to accept my CS cutter and mounted it in the drill press.

Ron Slosberg
Roswell, GA
RV-14A N3318S -- Flying

Build Log:
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