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Old 10-12-2010, 02:22 PM
Auburntsts's Avatar
Auburntsts Auburntsts is online now
Join Date: Jan 2005
Location: Tampa, FL
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Default At the risk of thread creep...

Paul what did you use to make your EFIS cutout in the picture?
Todd "I drink and know things" Stovall
RV-10 N728TT - Flying!
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Old 10-12-2010, 02:39 PM
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Mel Mel is offline
Join Date: Mar 2005
Location: Dallas area
Posts: 10,919
Default You sure about the 5/8" pilot hole?

Originally Posted by Ironflight View Post
Spot it with a #40, enlarge to 5/8? with a step drill, then slowly turn the screw with a nice long breaker bar until you hear the ?snap? - Your hole is ready! A rare moment of shop silence these days is worth the price, believe me?.
My punches have a 3/4" mandrel.
Mel Asberry, DAR since the last century. Over 1,000 certifications accomplished.
EAA Flight Advisor/Tech Counselor, Friend of the RV-1
Recipient of Tony Bingelis Award and Wright Brothers Master Pilot Award
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RV-6 Flying since 1993 (sold)
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Old 10-12-2010, 03:29 PM
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JonJay JonJay is offline
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Location: Battleground
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Default Greenlee is a brand...

Kind of like a Crescent Wrench (adjustable wrench), or "Vice-Grips"(locking adjustable wrench). Greenlee does make all kinds of punches but I dont believe they make the dual punch for aviation instruments but I could be wrong. Greenlee's main products are for the professional electrician.
No matter, whatever you call it, they are awesome and make quick easy work. I was lucky enough to borrow one for my panel.
There are square punches for common DB connectors but I dont think anything big enough for an EFIS or EMS.
Smart People do Stupid things all the time. I know, I've seen me do'em.

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Old 10-12-2010, 04:48 PM
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Ironflight Ironflight is offline
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Location: Dayton, NV
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1) For the EFIS holes? Much more noisy - cut-off wheel, drill holes for the corners, files to make the edges perfect, and scotchbrite disks to finish.

2) Yup Mel - 5/8" for mine. Just did four of them, and that's the size I drilled to for the mandrel with my step drill. Must be different manufacturers...

3) JonJay, you're right - I doubt mine was made my Greenlee - just used the term like (as you say) we use "Crescent Wrench" so folks know what 'm talking about. Wonderful thing to have in the box, no matter who makes it...

Paul F. Dye
Editor at Large - KITPLANES Magazine
RV-8 - N188PD - "Valkyrie"
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Old 10-12-2010, 06:56 PM
PCHunt PCHunt is offline
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Location: San Diego, CA
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Default -Caution-

Electrician hole punches are "sized" differently. For example, a 2" electrical punch would NOT make a 2" hole, it would make the proper hole for a so-called 2" electrical fitting.

Just make sure if you buy a punch you are sure of the exact diameter of it.
Pete Hunt, [San Diego] VAF #1069
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Old 10-14-2010, 04:57 PM
penguin penguin is offline
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Location: England
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Default Available for rent in the UK

For builders in the UK, Gloster Air Parts has one of these punches available for rent. Call Diana on 01252 617484.

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Old 10-21-2010, 12:08 AM
Flying Scotsman Flying Scotsman is offline
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Posts: 1,256

Greenlee makes really good tools...but just a heads-up. I don't know if it was my ****-*** technique, or the wrong material, but here's what happened:

I borrowed an electrician friend's Greenlee set to make the hole in the firewall for the cabin heat vent valve (whatever size that was). The punch did *not* punch out cleanly, but instead, on one side, it grabbed the stainless steel and stretched it out, at the same time jamming it in between the male and female parts of the die. A royal pain in the @ss to remove, and took some additional clean-up on the firewall to make it look perfect again (fortunately, had some material to sand away with a drum so everything came out very nice in the end).

I think it was the relatively thin stainless steel...these things are built for thicker non-stainless (electrical boxes), so they work fine on thicker aluminum, but it sure was a booger on that thin firewall stainless. I said, might have been something I did wrong, I dunno...but forewarned is forearmed.
Steve "Flying Scotsman"
Santa Clarita, CA
PP-ASEL, ASES, Instrument Airplane

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Old 10-22-2010, 11:02 AM
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Toobuilder Toobuilder is offline
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I'll agree that these punches are great, as I am doing the new -8 panel, but even MORE satisfying than turning the ratchet until the "pop" is using a hydraulic press to do the work for you. Just a couple of pumps and you are through like butter.
WARNING! Incorrect design and/or fabrication of aircraft and/or components may result in injury or death. Information presented in this post is based on my own experience - Reader has sole responsibility for determining accuracy or suitability for use.

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Harmon Rocket II -SDS EFI
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Old 10-22-2010, 05:16 PM
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LettersFromFlyoverCountry LettersFromFlyoverCountry is offline
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Originally Posted by Ironflight View Post
but if you do, think about borrowing one of these little wonders.
For those in Minnesota, I have one for the two holes I cut in the instrument panel that's available to anyone who'd like to use it. (I also give out my engine hoist. I vaguely track it around the airfield and I think I know where it is at the moment.)

Someday I think it would be cool if someone would build a nifty Web site for an RV tool crib, where you could look up the tool you want to borrow, click on your state, and then get a list of people who've registered the tools they're willing to lend.

Anyway, I've got a couple of sizes of Greenlee punches and other assorted tools that people can borrow if they want.

BTW, there is a technique involved in using these things. You have to compress and turn, back off, shift the rotation and repeat. You want to do this about 7 times. Then you go for broke. If you try to go for broke on the first try, you're probably going to have a problem.
Bob Collins
St. Paul, MN.
Blog: Letters From Flyover Country
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Old 10-22-2010, 10:08 PM
PJSeipel PJSeipel is offline
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Location: Albany, GA for the moment
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$2000, 3 months of work, learning software, test cutting, etc. but now I can cut a million copies of my panel no problem.

Learning a new skill....priceless. (oh, and it cuts square holes, round holes, and any other shape you want.)

PJ Seipel
RV-10 #40032
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