Saville
Well Known Member
HI all:
I've run into a problem which I am willing to bet is a well-solved problem on the VAF. So I need some suggestions.
Short Version:
I have a set of 6 plate nuts in two rows of three already installed - 3 holes on each of two flanges (RV-8 battery support structure).. I need to figure out a way to drill holes in a piece of 2024T3, 0.63 aluminum to precisely match those holes so I can screw this plate down onto the plate nuts.
You cannot get a drill up from the platenut side. Here's a picture of the holes on the flanges:
![](/proxy.php?image=http%3A%2F%2Fi22.photobucket.com%2Falbums%2Fb338%2Fsaville140%2FTrayFlangesANN.jpg&hash=c7582e7291d611795aa593233813ba26)
I've labeled the holes 1,2,3,4,5 and 6. The green arrow points to the plate nut hole. The hole above that in the picture is a builder mistake.
Long Version:
I want to install an Odyssey PC-925 AGM battery in the battery compartment which is aft of the aft baggage compartment. Presently there's a Gill battery there.
The footprint of the AGM will not fit the battery tray as built. So I have to rotate the battery 90 degrees and also install larger right angles onto the tray. Here is the old battery tray as it's installed in the airplane:
![](/proxy.php?image=http%3A%2F%2Fi22.photobucket.com%2Falbums%2Fb338%2Fsaville140%2FNoBattery_1.jpg&hash=d571a5fa842db75d961a17bd6b09f042)
Notice those two Tinnerman washers......problems......
Here is the new battery tray I built:
![](/proxy.php?image=http%3A%2F%2Fi22.photobucket.com%2Falbums%2Fb338%2Fsaville140%2FHoldDownsInstalled.jpg&hash=8f0bffe32c7201e979f76d2011edb93b)
I lived under the delusion that as the holes for screwing the trays to the mounting flanges are pre-drilled, the new tray will fit right right where the old tray was and those 6 screw holes will line up perfectly.
Well guess what? No way. Holes 2,5 and 6 are where they should be but 1, 3 and 4 are no where near. What is worse: look the old tray just laying on the flanges with the screws out:
![](/proxy.php?image=http%3A%2F%2Fi22.photobucket.com%2Falbums%2Fb338%2Fsaville140%2FOldTrayOnFlange.jpg&hash=4ca51d978e2014cc7f1528a3540cc7d6)
Lousy, appalling drilling. @#$%^%&*@#$
Ok after a session of swearing I tried to figure things out. First off, here is the new tray on the flanges. Note that holes 2,5 and 6 actually line up well:
![](/proxy.php?image=http%3A%2F%2Fi22.photobucket.com%2Falbums%2Fb338%2Fsaville140%2FNewTrayOnFlange.jpg&hash=00ccb3141efe02a2c6bf991d0f8a4723)
So here is my plan but I'm open to better ideas:
1) Get a piece of 2024-T3 0.63 thick aluminum and bore holes in it where the plate nuts ARE on the flanges. Screw that plate to the flanges.
2) Install 6 plate nuts on this new piece of aluminum in such a way that I can fasten the battery tray to the new piece of aluminum.
3) Lay the new battery tray on the new aluminum plate and screw it to the new plate.
That's the plan. Comments criticism better ideas welcome.
Now it turns out that I can use the old tray as a template for 4 of the 6 holes (1,2,5 and 6). But I need to figure out a way to locate where to drill holes for #3 and #4.
Here is a close up of #3:
![](/proxy.php?image=http%3A%2F%2Fi22.photobucket.com%2Falbums%2Fb338%2Fsaville140%2FNumber3HoleCloseup.jpg&hash=390093085bdcb60f4810db8616212cc9)
Here is a close up of #4:
![](/proxy.php?image=http%3A%2F%2Fi22.photobucket.com%2Falbums%2Fb338%2Fsaville140%2FNumber4HoleCloseup.jpg&hash=2375478cd15c8da842bc5313c9b2f058)
Number three actually fits one of the holes the builder drilled in the tray at that location so I might be able site that hole.
Number 4? No idea.
Perhaps making a template out of a piece of plexiglass.
I've run into a problem which I am willing to bet is a well-solved problem on the VAF. So I need some suggestions.
Short Version:
I have a set of 6 plate nuts in two rows of three already installed - 3 holes on each of two flanges (RV-8 battery support structure).. I need to figure out a way to drill holes in a piece of 2024T3, 0.63 aluminum to precisely match those holes so I can screw this plate down onto the plate nuts.
You cannot get a drill up from the platenut side. Here's a picture of the holes on the flanges:
![](/proxy.php?image=http%3A%2F%2Fi22.photobucket.com%2Falbums%2Fb338%2Fsaville140%2FTrayFlangesANN.jpg&hash=c7582e7291d611795aa593233813ba26)
I've labeled the holes 1,2,3,4,5 and 6. The green arrow points to the plate nut hole. The hole above that in the picture is a builder mistake.
Long Version:
I want to install an Odyssey PC-925 AGM battery in the battery compartment which is aft of the aft baggage compartment. Presently there's a Gill battery there.
The footprint of the AGM will not fit the battery tray as built. So I have to rotate the battery 90 degrees and also install larger right angles onto the tray. Here is the old battery tray as it's installed in the airplane:
![](/proxy.php?image=http%3A%2F%2Fi22.photobucket.com%2Falbums%2Fb338%2Fsaville140%2FNoBattery_1.jpg&hash=d571a5fa842db75d961a17bd6b09f042)
Notice those two Tinnerman washers......problems......
Here is the new battery tray I built:
![](/proxy.php?image=http%3A%2F%2Fi22.photobucket.com%2Falbums%2Fb338%2Fsaville140%2FHoldDownsInstalled.jpg&hash=8f0bffe32c7201e979f76d2011edb93b)
I lived under the delusion that as the holes for screwing the trays to the mounting flanges are pre-drilled, the new tray will fit right right where the old tray was and those 6 screw holes will line up perfectly.
Well guess what? No way. Holes 2,5 and 6 are where they should be but 1, 3 and 4 are no where near. What is worse: look the old tray just laying on the flanges with the screws out:
![](/proxy.php?image=http%3A%2F%2Fi22.photobucket.com%2Falbums%2Fb338%2Fsaville140%2FOldTrayOnFlange.jpg&hash=4ca51d978e2014cc7f1528a3540cc7d6)
Lousy, appalling drilling. @#$%^%&*@#$
Ok after a session of swearing I tried to figure things out. First off, here is the new tray on the flanges. Note that holes 2,5 and 6 actually line up well:
![](/proxy.php?image=http%3A%2F%2Fi22.photobucket.com%2Falbums%2Fb338%2Fsaville140%2FNewTrayOnFlange.jpg&hash=00ccb3141efe02a2c6bf991d0f8a4723)
So here is my plan but I'm open to better ideas:
1) Get a piece of 2024-T3 0.63 thick aluminum and bore holes in it where the plate nuts ARE on the flanges. Screw that plate to the flanges.
2) Install 6 plate nuts on this new piece of aluminum in such a way that I can fasten the battery tray to the new piece of aluminum.
3) Lay the new battery tray on the new aluminum plate and screw it to the new plate.
That's the plan. Comments criticism better ideas welcome.
Now it turns out that I can use the old tray as a template for 4 of the 6 holes (1,2,5 and 6). But I need to figure out a way to locate where to drill holes for #3 and #4.
Here is a close up of #3:
![](/proxy.php?image=http%3A%2F%2Fi22.photobucket.com%2Falbums%2Fb338%2Fsaville140%2FNumber3HoleCloseup.jpg&hash=390093085bdcb60f4810db8616212cc9)
Here is a close up of #4:
![](/proxy.php?image=http%3A%2F%2Fi22.photobucket.com%2Falbums%2Fb338%2Fsaville140%2FNumber4HoleCloseup.jpg&hash=2375478cd15c8da842bc5313c9b2f058)
Number three actually fits one of the holes the builder drilled in the tray at that location so I might be able site that hole.
Number 4? No idea.
Perhaps making a template out of a piece of plexiglass.
Last edited: