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01-26-2014, 09:14 PM
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Join Date: Mar 2008
Location: Toronto
Posts: 328
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Need to open up canopy rivet holes without removing plexi.
My canopy recently cracked " The Polar Vortex Got Me". I have removed the trim strip covering the center bow to check damage to the plexi.
The original holes where drilled as per plan 5/32 , IMHO, in retrospect, way too small. So I plan on doing a temporary repair using "Plastifix" on the crack but still need to open the existing holes to a more reasonable size, thinking around 1/4 inch.
The problem, how to drill the existing 5/32 holes to 1/4 with the plexi still attached to the frame. If I use a 1/4 plexi drill it will hit the frame before exiting the plexi, also, if I was able to get it through the plexi I would be unable to debure the exit point.
A unibit would not work as it would open up the 1/8 rivet hole in the frame.
Thoughts please.
Peter
__________________
RV7A New Dec 2013 - 360, C/S, slider
RV6 - 1600 Hours ---- Sold
Last edited by petersb : 01-27-2014 at 07:58 AM.
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01-26-2014, 10:02 PM
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Senior Curmudgeon
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Join Date: Sep 2005
Location: Dayton Airpark, NV A34
Posts: 15,420
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Couple of thoughts..............
I wonder if a heated rod would do the trick????
Melt the hole, not drill it.
Another idea would be a piloted reamer.........no idea if it would be safe on the plexi.
__________________
Mike Starkey
VAF 909
Rv-10, N210LM.
Flying as of 12/4/2010
Phase 1 done, 2/4/2011 
Sold after 240+ wonderful hours of flight.
"Flying the airplane is more important than radioing your plight to a person on the ground incapable of understanding or doing anything about it."
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01-26-2014, 10:21 PM
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Join Date: Mar 2008
Location: Toronto
Posts: 328
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Quote:
Originally Posted by Mike S
I wonder if a heated rod would do the trick????
Melt the hole, not drill it.
Another idea would be a piloted reamer.........no idea if it would be safe on the plexi.
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Yes, I was thinking about melting it. I did read in other threads that melting a hole might cause stress fractures.
Of course the plan is to replace the canopy this summer, so possible stress points might not be a problem in the short term.
__________________
RV7A New Dec 2013 - 360, C/S, slider
RV6 - 1600 Hours ---- Sold
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01-27-2014, 02:17 AM
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Join Date: Jun 2009
Location: hazelwood north vic
Posts: 176
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hi I believe a melted hole will have less stress risers than a drilled hole if you want to drill it you could grind a pilot point of 1/8 onto a 5/16 drill and grind the cutting edge of the 5/16 part flat like an end mill
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01-27-2014, 07:02 AM
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Join Date: Mar 2008
Location: Toronto
Posts: 328
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Quote:
Originally Posted by crashley
hi I believe a melted hole will have less stress risers than a drilled hole if you want to drill it you could grind a pilot point of 1/8 onto a 5/16 drill and grind the cutting edge of the 5/16 part flat like an end mill
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Good thought, I read that a forstner wood bit works well, requires using lubricant. The lubricant they suggest is water and baking powder. Water alone will cause rust on metal, the baking powder will stop the rusting.
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RV7A New Dec 2013 - 360, C/S, slider
RV6 - 1600 Hours ---- Sold
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01-27-2014, 10:04 AM
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Join Date: Jan 2005
Posts: 1,009
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If You Melt It In Place, You May Be Trading One Problem for Another?
Just thinking...
The melted plexi isn't going to vaporize. Will it flow into the threaded hole? If so, then re-tapping might fix that problem. On the other hand, if it somehow results in an uneven surface on either side of the plexi, that won't necessarily be good as far clamping that surface goes.
I'd also be a little nervous about any kind of square end bit being used to re-cut the hole. You might try cutting a piece from a small diameter, round chain saw file and chucking that in your drill or die grinder. Just a thought.
Terry, CFI
RV9A N323TP
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01-31-2014, 02:07 AM
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Join Date: Feb 2011
Location: Brisbane, Australia
Posts: 37
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Have you guys ever heard of a One-shot drill?
Usually used on carbon fibre composite panels, it is essentially a tapered lead straight flute reamer for your drill, with a cutting tip to start the hole.
http://www.mohawkeu.com/products.html
Look under the heading "one shot drill"
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