cutting hole in wing skin

[bobnoffs]

any tips on the best tool to use to cut an inspection hole in an rv-12 skin? not a round hole. i want a hole in the right wing same as factory in the left.

[DonFromTX]

Cutting the hole can be done in several ways, I personally prefer a nibbler, no deformation of the skin when making the hole.
To finish the hole, this is my best tool, makes a very neat flange to inset the cover, very professional. This one is $40 at Harbor Freight.
[IMG][/IMG]

[Mike S]

If you are trying to duplicate the access hatch like in the other wing, I would suggest you contact Vans, and order the cover plate, and the reinforcement ring and nutplates etc as needed.

When you get the parts, use the cover plate as a pattern to draw your cut lines where you want the new hatch, then use a step drill to open up the corners to the correct radius. After that is is a simple task to connect the four holes in the corners with a straight cut.

The air nibbler mentioned above is a good tool, but it cuts fast, and can be hard to control. Practice a bit on scrap before you touch the wing. You can also buy a hand operated nibbler that will do a fine job. A cutoff wheel will work just fine also, but they throw little bits of metal all over the place, including inside the wing-----so be aware.

Cut a bit undersized, and file or other method to get a nice fit to the cover. Install the reinforcement ring, and that is about all there is to it.

[bobnoffs]

thanks guys,
my skin is not mounted so chips are no big deal. i have a cut off wheel. i will be putting in a hole for a pitot too so maybe getting a nibbler is a good idea. i did plan on getting the parts from vans.
i haven't looked at my left wing hole but i guess i will need don's tool too if there is a flange.

[bill v]

i did the same thing on a 7 because it was easier to fit the tank with a hole here and if i have to replace the tie down i can do it through this hole. i did it like the second post but used a hand nibbler and made the hole slightly smaller i had spare material to use so made my own ring and cover but did it like left wing.

[rmartingt]

I cut that same hole on the RH skin to use as an access cover for my fuel transfer system (I'm making outboard tanks). I tried a variety of methods (cutoff wheel, mini endmill in a dremel, nibbler) but this was the most effective:

http://www.harborfreight.com/high-sp...saw-91753.html

Just make sure the skin is braced well before you start cutting. Drill holes for the start points, use the saw, and come back in with a file and sanding drum (in a dremel or grinder) to fit to final size.

[Jim T]

I used one of these for cutting the holes for my landing light and nav lights: http://www.micromark.com/power-nibbler,7779.html
Worked great!
I borrowed it from my neighbor. Otherwise I'd of just used a cutoff wheel in my Dremel.

Jim