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  #11  
Old 03-17-2015, 05:44 PM
rightrudder rightrudder is offline
 
Join Date: Mar 2014
Location: Laguna Hills, CA
Posts: 1,805
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Done! At least the upper cowling, and the fit is spot on. I didn't even need sliding receptacles for the corners. What I really like about this method is that the pilot hole needn't be all that precise, just less than the diameter of the cleco body. In fact, a little bigger is sometimes better, to make sure that the pointy end of the cleco is not exerting even the slightest side load on the cowling.

Once the holes were traced, I used a rat tail file to open the holes up to the Sharpie circles. Then, with baseline holes established, a Unibit to just under final diameter, then make the grommets a press fit with the tapered reamer.

Lower cowl should be far easier to mount with the aluminum strips rather than the receptacle plates, as match drilling will get everything centered up nicely.

HF's reamer works far better than it should for the price, but the loose T-handle is annoying. I fixed mine in place with some J-B Weld.





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Doug
RV-9A "slider"
Flew to Osh in 2017, 2018 & 2019!
Tail number N427DK
Donation made for 2020
You haven't seen a tree until you've seen its shadow from the sky -- Amelia Earhart

Last edited by rightrudder : 03-17-2015 at 05:50 PM.
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  #12  
Old 03-17-2015, 05:49 PM
wirejock's Avatar
wirejock wirejock is offline
 
Join Date: Oct 2005
Location: Estes Park, CO
Posts: 3,947
Default Holes

Nice job Doug.
Gotta remember that tip.
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Larry Larson
Estes Park, CO
http://wirejockrv7a.blogspot.com
wirejock at yahoo dot com
Donated 12/03/2019, plus a little extra.
RV-7A #73391, N511RV reserved (2,000+ hours)
HS SB, empennage, tanks, wings, fuse, working finishing kit
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I cannot be, nor will I be, held responsible if you try to do the same things I do and it does not work and/or causes you loss, injury, or even death in the process.
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  #13  
Old 03-30-2015, 03:01 PM
NBowers NBowers is offline
 
Join Date: Dec 2006
Location: Leesburg, FL
Posts: 89
Default Skybolt Fasteners 15/32 Drill

The Unibit-1 has a 15/32 step...last step before the final 1/2 step.

Typically, before composites came into being and everything was aluminum, the 15/32 hole (.4687) would allow the grommet to clear the retainer ridge that is .471 to .472 wide by slanting the grommet when you insert it into the panel. The typical grommet has a groove/undercut to accommodate the retainer. We have high shear grommets made specifically for the Vans series aircraft, however, there remains the groove for the retainer.

All this works great on .032-.040 aluminum or composite. Thicker panels (aluminum or composite) do not allow enough insert clearance, thus, a .500 hole (.472 to be exact) might be required....depending on how tight you want the grommets to fit. The standard undercut allows some float in the NS or OS style grommets. By eliminating this float, we are allowing a tighter fit with reduced cowling shift and hole wear over time but we are also required to have aligned holes.

Like everything, perfection comes at a price.

May I add that Skybolt is promoting a 20% sale on Complete Vans RV Fastener Kits from April 1st through April 26th (end of Sun N Fun). Look for us to be back in 2016 as a vendor with plenty of kits and advice, including cowling mock ups for the RV series. Skybolt provides patented interlocking support plates, our DiamondHead series studs, high shear grommets, extensive how-to instructions. The DiamondHead stud are super hard with a machined facing to prevent galling such that they will look as clean after thousands of cycles as they did in the bag they came in.

Call us or go on line....1-800-223-1963 www.skybolt.com If you have questions, give us a call.

Ned Bowers
RV4, RV8, B17, B24, B everything else, L39, Beech everything, Cub.....more Vans...time for a 9....older.
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  #14  
Old 03-30-2015, 04:17 PM
rightrudder rightrudder is offline
 
Join Date: Mar 2014
Location: Laguna Hills, CA
Posts: 1,805
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Wow, very thorough explanation, Ned! You're right about the Unibit, but I guess I was just a little scared that I would open up the holes too much, so I hand-reamed them for a press-fit of each grommet. That's a very high quality Unibit, incidentally....cuts fiberglass effortlessly.

I'm really liking the Skybolts. The cowling sort of snaps in place before you give the 1/4-turn cinch, as the fasteners locate in the plate holes.
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RV-9A "slider"
Flew to Osh in 2017, 2018 & 2019!
Tail number N427DK
Donation made for 2020
You haven't seen a tree until you've seen its shadow from the sky -- Amelia Earhart
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