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  #1  
Old 03-01-2008, 09:09 AM
jmbrwn's Avatar
jmbrwn jmbrwn is offline
 
Join Date: Aug 2007
Location: Carrollton, GA
Posts: 313
Unhappy Drilling lead counterweights

Well, I broke my drill bit inside the lead elevator counterweight. Can't get it out, and can't drill through it. Any suggestions?
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RV6, Christen Eagle II(Sold)
ATP, CFII, A-IGI, A&P/IA
Carrollton, GA
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  #2  
Old 03-01-2008, 09:35 AM
Mike Ice Mike Ice is offline
 
Join Date: Apr 2006
Location: Sedro Wooley, WA
Posts: 147
Default drilling lead

Hello,

Did the drill go all the way through the lead weight?

If so the following might work.

Put on some gloves and safety glasses. Prop the lead weight up between some blocks of wood. Take a punch and a big hammer and beat the drill bit through the lead weight.

Lead is tough to drill. Go slow and back out of the hole frequently to clear the shavings.

anyone else got any ideas?

Mike
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  #3  
Old 03-01-2008, 09:38 AM
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jmbrwn jmbrwn is offline
 
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Location: Carrollton, GA
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Default

Thanks Mike....good idea, but the bit didn't get all the way thru. I'm thinking the easiest thing to do is order a new counterweight. Thanks for the quick reply, and I'll use your suggestions.
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RV6, Christen Eagle II(Sold)
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Carrollton, GA
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  #4  
Old 03-01-2008, 11:01 AM
ncarmon ncarmon is offline
 
Join Date: Nov 2007
Location: Ohio
Posts: 89
Default tip...

Try a pair of needlenose vice grip. Put the noses it into the holes where the drill bit ain't (into the open twist of the bit). Use crescent wrench on the vice grips to back it out.

By the way, you might try putting it in the freezer before you try it.
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  #5  
Old 03-01-2008, 12:39 PM
jrvssgl jrvssgl is offline
 
Join Date: Oct 2007
Location: Oyen, Ab
Posts: 173
Default Pay the Freight?

Counterweights do not have to be pretty when installed, just as long as the shape is right. You will be able to fill the holes with resin and microballoons to obtain a good finish. I would just try pounding the bit with a punch until it comes. If all else fails I have a brand new counterweight here you can have. Just pay the freight. Best of luck to you.

Last edited by jrvssgl : 03-01-2008 at 12:45 PM. Reason: correction
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  #6  
Old 03-01-2008, 01:39 PM
gpiney gpiney is offline
 
Join Date: Jan 2005
Location: The Beautiful NJ Shore
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Default

The -7 and -8 have totally different counterweights.
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RV-8 2547
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  #7  
Old 03-01-2008, 01:55 PM
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jmbrwn jmbrwn is offline
 
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Location: Carrollton, GA
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Default

Quote:
Originally Posted by jrvssgl View Post
Counterweights do not have to be pretty when installed, just as long as the shape is right. You will be able to fill the holes with resin and microballoons to obtain a good finish. I would just try pounding the bit with a punch until it comes. If all else fails I have a brand new counterweight here you can have. Just pay the freight. Best of luck to you.
Thanks Jarvis, I appreciate the offer. I went ahead and ordered a new one from Van's....it's only $9.70. I'll use the other one for now, and use the new one when it arrives for the left elevator.
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RV6, Christen Eagle II(Sold)
ATP, CFII, A-IGI, A&P/IA
Carrollton, GA
Lyon?s Landing
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  #8  
Old 03-02-2008, 06:39 AM
timandmeli timandmeli is offline
 
Join Date: Nov 2006
Location: Coffee Springs, Al
Posts: 124
Default Lead Counterweight issue

I did exactly the same thing as you have described. My soultion was to drill multiple holes around the periphery of the broken bit with a small drill bit until we were able to pull it out with needle nose vise grips. YMMV
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Coffee Springs, Al
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  #9  
Old 03-24-2011, 12:47 AM
Raden Raden is offline
 
Join Date: Jun 2009
Location: NorCAL
Posts: 16
Default Thought I would add my sollution for future searches

I found this thread today when I did the exact same thing, broke off a 3/32 drill bit in my lead counterweight. I tried to punch it out but it would not come through the other side. My fault for using a cheap bit (didn't want to use my good bits on lead)

I enlarged the hole which ended up being an oblonged kind of 3 sided cloverleaf shape. I was finally able to punch out the broken drill bit then grab it with needle nose pliars.

I melted some lead (blow torch and throw away pot) and poured it into the messed up hole creating a lead patch as it were. I made sure the lead was all the way though the hole and both side were sealed with new lead. I then filed down the excess lead that spilled up above the hole. I placed the the lead counterweight back into the counterweight skin/rib assembly. I then was very careful to drill slow and use a good drill bits enlarging the hole to final size slowly.

You can barely tell the hole was filled with new lead and it seems to hold well. I was concerned about the cold joint between the old and new lead, but the part is sandwiched between the ribs and skin so if the lead flakes off in the hole it will be held in place for sure.

Another solution I thought of was drilling two bolt holes on each side of the broken drill bit hole.

I had just spent a long time with a hacksaw and file shaping the right elevator counterweight and I wanted to salvage the part if I could.

Branden
RV-8 Empenage
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  #10  
Old 03-24-2011, 06:27 AM
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Mel Mel is online now
 
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Location: Dallas area
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Default

Melt it down and re-pour it. We had to pour all of our balance weights back in the day.
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RV-6 Flying since 1993 (sold)
<rvmel(at)icloud.com>
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