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Drilling Holes in Tubing and Cutting Slots

rockitdoc

Well Known Member
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Scan.jpegDrilling holes isn't a problem, but drilling them centered on the diameter is. I've found various jigs online, but they all are of specific drill sizes and so far, none of the sizes we use.

Then, there're the slots that must be cut in the L and R pushrods for the canopy release. A handheld dremmel could work, but it would be clunky and might not cut straight.

The figure shows what I'm talking about if the explanation wasn't clear.
 
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easy peesy

To get them straight aligned on each end just walk over to a door way. Put the tube in the 90 degree corner of the jam and draw the line down.
Then use the paper trick to get to the other side.
Art
 
V-drill guide clamped to the tube

I've just clamped a drill guide along the tube then drilled from one side & out the other. The holes have always come out on centreline (the V part of the guide lines it up with the tube) and in line with each other. There are drill guides available for 1/4", and for most of the other common sizes used. You could also drill a size smaller then ream through to ensure the holes are aligned and clean.

As for the slots, hacksaw & file, or an angle grinder & thin cutting disc then file..
 
I have used this method for similar:
Cut the thin slot using a hacksaw.
Use this slot to level the tube in a vise by putting a piece of scrap in the slot. (Your eye is quite accurate)
Start the next slot with a triangular file to get it level with the first slot. The triangle file let’s use some “English” to adjust your starting points.
Finish the slot with a file. Work carefully to keep it going straight. Angleing it helps.
I use a needle file for 1/8” slots.
Use the same slots to level the tube for the hole drilling.

Doing the slots first gives you a way to square up for the holes.
 
Using math

Multiply the diameter x 3.14 divided by the number of holes you want. Mark the distances on a piece of paper or tape and put on the tubing. Drill from both sides.
I’ve only used this method on larger pipe but it should work on smaller tubing as well if you mark it accurately. Not as easy as the video using paper but another alternative
 
Howdy Scott. Here is a link to a tool I use all the time to locate a hole centered over the radius of a tube.

https://www.amazon.com/Benchmark-To...&keywords=center+finder&qid=1612560773&sr=8-5

Here is a link to my video demonstrating how to use the tool:

https://www.youtube.com/watch?v=tuIlKeGGiN0

Here is a link to my 3 part series of videos fabricating and installing the canopy jettison. ( Just posted last week!)

https://www.youtube.com/watch?v=WUBNMol22Hg

Perhaps something in these videos will be of use.
 
One more thing....I cut the slits first; before drilling the holes. To get the holes 90 degrees to the slit, slide a piece of 1/16" or 1/8" thick plywood, (depending on which end you are drilling in the tube) into the slit and then rotate the tube in the vise under the drill chuck until the plywood is 90 degrees to the drill. You can even place a small square on the plywood and rotate the tube until the square rests precisely with the drill chuck. Might make sense when you actually get to this point in fabricating the linkage.
 
Drilling in Tubes and Cutting Slots

Howdy Scott. Here is a link to a tool I use all the time to locate a hole centered over the radius of a tube.

https://www.amazon.com/Benchmark-To...&keywords=center+finder&qid=1612560773&sr=8-5

Here is a link to my video demonstrating how to use the tool:

https://www.youtube.com/watch?v=tuIlKeGGiN0

Here is a link to my 3 part series of videos fabricating and installing the canopy jettison. ( Just posted last week!)

https://www.youtube.com/watch?v=WUBNMol22Hg



Perhaps something in these videos will be of use.
Thanks Mike. Very helpful videos! But, it cost me. That x-y table on your mill is just what I was looking for. And, those center drills are the perfect solution to drill 'wander'. I got a x-y table to install on my drill press to make it a poor-man's mill. You'll make me a machinist's mate, yet!

BTW, the trick for lining up the hole perpendicular to the slot is very handy and necessary.
 
You are quite welcome. The good news about the X/Y table, mill, center drills, center finder, etc. they are not aircraft specific; you'll use them for all kinds of cool things.

Without the slot being 90 degrees to the hole, the linkage will bind or at least be tight and difficult to move.

Feel free to contact me if you any other questions.
 
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