Aileron Bracket hole?

[s10sakota]

I just noticed on the plans that this hole (see red arrow) has to be counter-sunk. The countersink cage will not work on this hole because of the nature of the angled piece of aluminum, so how do I countersink it?

I tried a few turns with my deburring tool but that doesn't work. Is there another tool I don't know about that I can use to countersink this hole?

Thanks!

 

[pilotkms]

Grinder

Its been awhile, but i think this is where i took the cage of the countersink and ground it down to fit in that spot. I figured there would be more places just like it and i think there was/is. There may be another tool but this worked for me.

 

[miko38]

Try taking the counter sink cage off. I would practice on a scrap piece first, just go slow and check the depth often.

 

[rzbill]

Basic question.
When you used the deburring tool, did you use the piloted countersink bit in it? The chattering looks like non-piloted effects.

I have countersunk many holes "freehand" using deburr handle and countersink bit. It is easy and does a good job if you take your time and are careful.

 

[s10sakota]

Thanks for the replies. Ah! I did not use a piloted countersink when I did this and I stopped because of the chattering. I didn't think to use one

I'll try some of your suggestions and I'm sure it will come out great.

 

[YellowJacket RV9]

On a number of occasions I have used my angle drill adapter with a piloted countersink cutter to countersink in tight places, free hand. Go slow, keep the bit perpindicular, and it isn't top hard.

Chris

 

[Iluke]

Let me add another vote for doing it freehand. I chuck the piloted countersink cutter into a cordless drill with no cage and just turn it real slowly taking only a little bit at the time, testing the depth often with a rivet. The risk, of course, is going too far, but I have not found that to be a problem if I'm (1) patient, and (2) use only the 3-flute cutter. The 1-flute cutter sold by Cleveland and others cuts too fast for me to control freehand. I find the 3-flute cutter to be easy to control if you are careful.

 

[Arie]

+1 on the freehand method. I did those holes by using the countersink cutter screwed onto a drill extention and turning it slowly with my cordless drill. Worked great...

 

[longranger]

I'm not positive, but I seem to remember using my deburring extension and a countersink bit in the drill press (run at low speed or turn the chuck by hand to avoid whipping). I've also done quite a few freehand.