Preferred cutting method

[jlfernan]

I'm getting ready to order my QB wings and am struggling with what is the best method for cutting the holes in the LE for landing lights?

[Alschief]

I used a Dremel Tool with a fiber disk. It worked fine.

AL Smith
N495AB
RV6 Wiring/FF
KEOS

[Captain_John]

I second that!

After using the abrasive disk, I switched to the carbide side cutter and finished it off with the drum sander.

Would do it al over again the same way!

CJ

[alpinelakespilot2000]

Agree with above, except that I'd add to CJ's that I, of course, followed up then dremel drum sander with hand sandpaper, emery paper, and then scotchbrite pad. Turned out great, and the cutouts are actually pretty square, believe it or not!

Get as close as you dare to the final line in your initial dremel cutting disk cut. That will save you a lot of time with the drum sander. Just need to keep a steady hand though. As usual with repetitive tasks, first side took about 3 hours, the second took about 30 minutes and created a lot less anxiety. Good luck.

[hevansrv7a]

Of course you could use the wingtip type of light and skip cutting the LE.
h

[az_gila]

I find this to be the best Dremel cutting wheel. The 2 inch diameter makes it much easier to keep square to the work and follow lines easier. It also gives a faster cutting speed.

It's not a Dremel product, but comes from House of Balsa.. most hobby stores should have it...

House of Balsa Cutting disk

It's far better than the puny 1 inch disks Dremel sells....
It's also great at cutting steel parts....

gil in Tucson

[Rick S.]

I'll second the HOB Tuff Grind disks, I've used them for years and never had one break or shatter. I've worn them all out. They are reinforced with a weave and worth every penny. Plus you get to make a trip to the hobby shop and see how inexpensive R/C airplanes are now that your building an RV!!

Rick S.
RV-10
Fuselage

[N916K]

To get all the radii the same find a cylinder that's about the right radius and use spray mount to attach sandpaper to it. It makes getting all the corners the same very easy.

[scard]

Any you probably have a great selection of cylinders for finishing purposes in your toolbox full of sockets.

[ericwolf]

I used a fiber cut off wheel on the dremel also, but I didn't cut very close to the final line. Once the hole was (very) rough cut, I used my snips to get close to the line, then used drum sanders and files to get the rest of the way. I felt that creeping up on the final cut line with these different tools gave me the most control.