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  #1  
Old 12-04-2019, 09:19 PM
Outrider Outrider is offline
 
Join Date: Aug 2019
Location: Texas
Posts: 15
Default Deburring. How picky?

I?ve been putting together my shop and practicing on a couple Vans toolbox kits. The first one I barely deburred at all because I just wanted to get to the riveting part. The second one I hand sanded all the cut edges I could reach with sandpaper. I noticed there were a lot of little nooks and crannies I couldn?t easily reach with any tools without spending an inordinate amount of time.

That brought the question to mind: Just how picky do I need to be about deburring and polishing every single edge? I imagine on the plane, just like the tool box, there are a lot of hard to reach places, like the inside of the tabs on wing ribs, etc.

So, do I need to prepare to spend the majority of my build time hunting down and polishing imperfections in hard to reach corners with a jewelers loupe, or is there a happy medium there somewhere, and where would that be exactly?
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  #2  
Old 12-04-2019, 11:06 PM
akabud akabud is offline
 
Join Date: Jan 2019
Location: Galt, CA
Posts: 70
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You don't have to deburr every thing. Just the parts you don't want to crack.
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  #3  
Old 12-05-2019, 01:14 AM
Pittsartist Pittsartist is offline
 
Join Date: Aug 2013
Location: UK
Posts: 160
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Sound like you may not have a Scotchbrite wheel ?

I'd sooner cut a good sized lawn with scissors than debur an RV kit without one !

Seriously, if not then it's probably one of the best tooling investments you can make

Personally, I try to debur all the edges of all my parts. Once you have the right set of tools this is not too difficult ... but still takes time.

My rough process is

1) Break long edges and large diameter radiuses with a deburing tool (swisstool) or flat file
2) Get into corners with a round needle file
3) Use the scotchbrite wheel to finesse
4) 240 grit abrasive to finish. I know when it's done because I dont feel any risk of cutting myself on the part and cannot feel any nicks or irregularities in the edges.

Use your imagination on where cracks are most likley to form ... but pay very particular attention to critical areas (eg If you do an 'Emp kit 1st then anywhere around the H/S centre section)

As I said, it takes time ...... but you are building an aeroplane
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Last edited by Pittsartist : 12-05-2019 at 02:51 AM.
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  #4  
Old 12-05-2019, 02:51 AM
tgmillso tgmillso is offline
 
Join Date: Nov 2012
Location: Launceston, Tasmania, Australia
Posts: 774
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https://www.vansaircraft.com/wp-cont.../RV-ALL_05.pdf

It?s all covered in section 5.2 of the manual.

Tom.
RV-7
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  #5  
Old 12-05-2019, 06:43 AM
rocketman1988 rocketman1988 is offline
 
Join Date: Jun 2010
Location: Sunman, IN
Posts: 2,189
Default Debur

Something to be said, as well, is that a lot of people overdo the deburring process.

You do not need to polish every edge to a mirror finish, and you do not need to remove a lot of material...

Look at the mainstream GA aircraft that have been flying for 50+ years; run your finger over the inside edge of a lightening hole (carefully)...
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  #6  
Old 12-05-2019, 08:01 AM
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Draker Draker is offline
 
Join Date: Jun 2016
Location: Livermore, CA
Posts: 397
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I do 90% of my deburring on my Scotchbrite wheel. The inside areas of flanges and relief holes are tricky, and for these I use hand tools. I don't go for a mirror finish either, or sand them down, but I do make sure I can run my finger down each edge and not feel any nicks or deformities.

Also, don't use a Scotchbrite wheel on large skins or you'll get this: http://www.vansairforce.com/communit...d.php?t=156306
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  #7  
Old 12-05-2019, 08:28 AM
Robin8er Robin8er is offline
 
Join Date: Sep 2015
Location: Socal
Posts: 453
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I think somewhere in the Van's manual its says something to the effect of "if you can run your finger across the edge without fear of being cut then its good". I tend to agree with the.

Just round the corners and make sure the edges are smooth. The deburring wheel works great, but so do files, scotch brite pads, edge deburring tools etc. It usually only takes about 1 minute per part.
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  #8  
Old 12-05-2019, 09:26 AM
Outrider Outrider is offline
 
Join Date: Aug 2019
Location: Texas
Posts: 15
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Quote:
Originally Posted by Pittsartist View Post
Sound like you may not have a Scotchbrite wheel ?

I'd sooner cut a good sized lawn with scissors than debur an RV kit without one !

Seriously, if not then it's probably one of the best tooling investments you can make

You guys are helping me fill up my shopping cart over at one of our favorite suppliers.

Which grade of Scotchbrite wheel do you recommend? 7A, 7s or other?
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  #9  
Old 12-05-2019, 09:53 AM
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fl-mike fl-mike is offline
 
Join Date: Jul 2005
Posts: 1,346
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The funny thing is that the deburring and smoothing should really be done BEFORE Van's forms the parts. Kind of backwards to remove crack initiators/stress risers AFTER bending!
I would pay good money to Van's to deburr the edges of all formed parts in the flat. Those rib and bulkhead notches and corners are a pain.
I'll (somewhat) gladly do the holes and flat part and sheet edges.
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  #10  
Old 12-05-2019, 10:45 AM
JwWright57 JwWright57 is offline
 
Join Date: Dec 2016
Location: Charlotte, NC
Posts: 181
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Yeah I think everyone has a story about deburring wing ribs. It took me FOREVER on my 12 to do all the ribs. I ended up using sandpaper, deburring tool, Big Scotchbrite wheel on the long edges and a little scotchbrite on the dremel tool.

You can make the dremel tool bits out of these;

http://www.cleavelandtool.com/3M-Cut.../#.XelBhvlKiUk

Cut them into pie shapes and screw onto a dremel mandral
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