Page 1 of 2

Skin blemishes

Posted: Sat Feb 18, 2012 10:59 am
by Jesse Jenks
I had a downer day today. Not as bad as New Orleans, but...
I was getting ready to install the bottom skin on my first wing, I rolled
off the plastic using a dowell, then discovered a row of dents along half of
the skin. I am pretty sure they were caused by removing the plastic, but I
don't know why. I used the same technique on the tail skins, and even the LE
skin without any problem. Anyway, I don't want to use the skin. I am
thinking of getting a 4X12' sheet from ACS or other, and just duplicate it.
Are there any issues with doing it that way? I would be drilling right to
#30, so the holes won't be as perfect but I don't see a way around that. I
just don't know if the duplicate holes will be aligned well enough to go
down smooth on the spars and stringers. I could use an egg cup bushing to
keep the drill as square as possible.
Anyone have experience with this?
I could also order another skin from MAM, but I think I would be better off
with a blank sheet.
Thanks
Jesse





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Skin blemishes

Posted: Sat Feb 18, 2012 10:59 am
by Jesse Jenks
Thanks for the replies guys,
I would like to have hope that it would be all OK once riveted in place, but
I really don't think so. I don't want to cringe every time I look at my
right wing. There is a pattern of small dents about 6" long that repeats
with even spacing for about half the length of the skin. It may be possible
to burnish them out or something, so I guess I should ask around as you say.
It looks pretty bad to me though.
The skin is already drilled to #30 along with the ribs, stringers, and
spars. If I started over with a new pre punched skin then would I just drill
it out to #30 while off the structure and hope the holes line up? I would be
worried that the holes I already had drilled in the structure might be
slightly misaligned with the new skin because they would have not been
enlarged from #40 to #30 at the same time. That's why I thought it would be
better to start with a blank sheet and use the original skin as a template.
Although I would have to drill to #30 on the first go, the holes should be
accurately located by the original skin. Also the holes around the tank area
where the tank skin joins to the main skin are not pre punched, but where
added by me, and would not be easy to locate without using the original skin
as a template.
Jesse
From: Jim Cole <jcole@rangroup.com>
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: Re: Skin blemishes
Date: Wed, 31 Aug 2005 22:27:34 -0400

Hi Jesse,

I wanted to extend my tanks to 5 bays from the original 3 bays so I
ordered a new piece of 6061 from a local supplier in Toronto and used
the old skin as a template. They cut it to size and I had a large table
and a piece smooth press board underneath so that I could drill through
with out worrying about it. It worked fine - especially after I bought a
cobalt #40 drill that was sharp and stayed sharp but certainly was time
consuming. I used clecos and clecoed it to the template and the table as
I progress in a sequence from one end to the other.

I'm with Bob though - check with someone with experience locally because
you just might be surprised at what can be done.

Good Luck
Jim (now rebel 333)
Hi Jesse !

Maybe you could find a nearby builder to have a look at that skin -
it might be fixed, or not as bad as you might think ... (optimistically
!)
Perhaps someone from the RAA chapter might have a trick or 2 ...

Hard to imagine that you'd be better off drilling your own - I think
the CNC punch has a tolerance of less than one thousandth of an inch in
the 12 feet !!
.....bobp

-------------------------------orig.-------------------------
On Wednesday 31 August 2005 09:47 pm, Jesse Jenks wrote:

I had a downer day today. Not as bad as New Orleans, but...
I was getting ready to install the bottom skin on my first wing, I
rolled
off the plastic using a dowell, then discovered a row of dents along
half of
the skin. I am pretty sure they were caused by removing the plastic, but
I
don't know why. I used the same technique on the tail skins, and even
the LE
skin without any problem. Anyway, I don't want to use the skin. I am
thinking of getting a 4X12' sheet from ACS or other, and just duplicate
it.
Are there any issues with doing it that way? I would be drilling right
to
#30, so the holes won't be as perfect but I don't see a way around that.
I
just don't know if the duplicate holes will be aligned well enough to go
down smooth on the spars and stringers. I could use an egg cup bushing
to
keep the drill as square as possible.
Anyone have experience with this?
I could also order another skin from MAM, but I think I would be better
off
with a blank sheet.
Thanks
Jesse





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Skin blemishes

Posted: Sat Feb 18, 2012 10:59 am
by Alan Hepburn
Unless it's awfully bad, go ahead and use it. I did the same thing, and can
hardly find the spots any more. The appearance will improve once the
riveting is complete. Perhaps it's just that every rivet is an
imperfection, so the blemishes that show on a virgin sheet of metal tend to
get lost in the noise. Also, unless you plan to keep the airplane in a
glass case, it will accumulate a few more blemishes over time.

Al





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Skin blemishes

Posted: Sat Feb 18, 2012 10:59 am
by Bob Patterson
Hi Jesse !

Maybe you could find a nearby builder to have a look at that skin -
it might be fixed, or not as bad as you might think ... (optimistically !)
Perhaps someone from the RAA chapter might have a trick or 2 ...

Hard to imagine that you'd be better off drilling your own - I think
the CNC punch has a tolerance of less than one thousandth of an inch in
the 12 feet !!
.....bobp

-------------------------------orig.-------------------------
On Wednesday 31 August 2005 09:47 pm, Jesse Jenks wrote:
I had a downer day today. Not as bad as New Orleans, but...
I was getting ready to install the bottom skin on my first wing, I rolled
off the plastic using a dowell, then discovered a row of dents along half of
the skin. I am pretty sure they were caused by removing the plastic, but I
don't know why. I used the same technique on the tail skins, and even the LE
skin without any problem. Anyway, I don't want to use the skin. I am
thinking of getting a 4X12' sheet from ACS or other, and just duplicate it.
Are there any issues with doing it that way? I would be drilling right to
#30, so the holes won't be as perfect but I don't see a way around that. I
just don't know if the duplicate holes will be aligned well enough to go
down smooth on the spars and stringers. I could use an egg cup bushing to
keep the drill as square as possible.
Anyone have experience with this?
I could also order another skin from MAM, but I think I would be better off
with a blank sheet.
Thanks
Jesse





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Skin blemishes

Posted: Sat Feb 18, 2012 10:59 am
by Jim Cole
Hi Jesse,

I wanted to extend my tanks to 5 bays from the original 3 bays so I
ordered a new piece of 6061 from a local supplier in Toronto and used
the old skin as a template. They cut it to size and I had a large table
and a piece smooth press board underneath so that I could drill through
with out worrying about it. It worked fine - especially after I bought a
cobalt #40 drill that was sharp and stayed sharp but certainly was time
consuming. I used clecos and clecoed it to the template and the table as
I progress in a sequence from one end to the other.

I'm with Bob though - check with someone with experience locally because
you just might be surprised at what can be done.

Good Luck
Jim (now rebel 333)
Hi Jesse !

Maybe you could find a nearby builder to have a look at that skin -
it might be fixed, or not as bad as you might think ... (optimistically !)
Perhaps someone from the RAA chapter might have a trick or 2 ...

Hard to imagine that you'd be better off drilling your own - I think
the CNC punch has a tolerance of less than one thousandth of an inch in
the 12 feet !!
.....bobp

-------------------------------orig.-------------------------
On Wednesday 31 August 2005 09:47 pm, Jesse Jenks wrote:

I had a downer day today. Not as bad as New Orleans, but...
I was getting ready to install the bottom skin on my first wing, I rolled
off the plastic using a dowell, then discovered a row of dents along half of
the skin. I am pretty sure they were caused by removing the plastic, but I
don't know why. I used the same technique on the tail skins, and even the LE
skin without any problem. Anyway, I don't want to use the skin. I am
thinking of getting a 4X12' sheet from ACS or other, and just duplicate it.
Are there any issues with doing it that way? I would be drilling right to
#30, so the holes won't be as perfect but I don't see a way around that. I
just don't know if the duplicate holes will be aligned well enough to go
down smooth on the spars and stringers. I could use an egg cup bushing to
keep the drill as square as possible.
Anyone have experience with this?
I could also order another skin from MAM, but I think I would be better off
with a blank sheet.
Thanks
Jesse





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Skin blemishes

Posted: Sat Feb 18, 2012 10:59 am
by bransom
Jesse,
If nothing else, you have my sympathy -- I know that would not make my day.
Other more experienced than I will certainly know better, but I would think
that match drilling with #30 to a new sheet, using clecos as you go would be
fine. I've done some small parts straight from #30 and wondered if it would
help to have a small spacer in between so that the full diameter of the #30
is in the top hole before starting in on the fresh piece underneath, but I've
had fine results without this. Again though, this on small pieces where if
there was a very slight bit of drill wandering it is unnoticable in final
product.
Good luck, I'm sure you'll find a good solution.
-Ben
I had a downer day today. Not as bad as New Orleans, but...
I was getting ready to install the bottom skin on my first wing, I rolled
off the plastic using a dowell, then discovered a row of dents along half
of
the skin. I am pretty sure they were caused by removing the plastic, but I
don't know why. I used the same technique on the tail skins, and even the
LE
skin without any problem. Anyway, I don't want to use the skin. I am
thinking of getting a 4X12' sheet from ACS or other, and just duplicate it.
Are there any issues with doing it that way? I would be drilling right to
#30, so the holes won't be as perfect but I don't see a way around that. I
just don't know if the duplicate holes will be aligned well enough to go
down smooth on the spars and stringers. I could use an egg cup bushing to
keep the drill as square as possible.
Anyone have experience with this?
I could also order another skin from MAM, but I think I would be better off
with a blank sheet.
Thanks
Jesse




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Skin blemishes

Posted: Sat Feb 18, 2012 10:59 am
by Ken
Yes I agree. A sheet of thick brown paper between the aluminum sheets if
the top sheet is only 0.020 and a good quality 135 degree split point
bit for the same reason. For large sheets one can put white styrofoam
underneath to keep everything flat as you insert clecos.

Ken

bransom@dcsol.com wrote:
Jesse,
If nothing else, you have my sympathy -- I know that would not make my day.
Other more experienced than I will certainly know better, but I would think
that match drilling with #30 to a new sheet, using clecos as you go would be
fine. I've done some small parts straight from #30 and wondered if it would
help to have a small spacer in between so that the full diameter of the #30
is in the top hole before starting in on the fresh piece underneath, but I've
had fine results without this. Again though, this on small pieces where if
there was a very slight bit of drill wandering it is unnoticable in final
product.
Good luck, I'm sure you'll find a good solution.
-Ben




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Skin blemishes

Posted: Sat Feb 18, 2012 10:59 am
by bransom
I too really like the split point "jobber" bits -- I've gotten mine from
Brown Tool but I'm sure many source the same thing. Cheap enf to toss when
worn out, yet last pretty long since we're on soft aluminum, and they put
holes where you want them more easily than other bits, IMO.
-Ben
Yes I agree. A sheet of thick brown paper between the aluminum sheets if
the top sheet is only 0.020 and a good quality 135 degree split point
bit for the same reason. For large sheets one can put white styrofoam
underneath to keep everything flat as you insert clecos.

Ken

bransom@dcsol.com wrote:
Jesse,
If nothing else, you have my sympathy -- I know that would not make my
day.
Other more experienced than I will certainly know better, but I would
think
that match drilling with #30 to a new sheet, using clecos as you go would
be
fine. I've done some small parts straight from #30 and wondered if it
would
help to have a small spacer in between so that the full diameter of the
#30
is in the top hole before starting in on the fresh piece underneath, but
I've
had fine results without this. Again though, this on small pieces where
if
there was a very slight bit of drill wandering it is unnoticable in final
product.
Good luck, I'm sure you'll find a good solution.
-Ben




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Skin blemishes

Posted: Sat Feb 18, 2012 10:59 am
by Mike Betti
I had the same problem doing the same thing. I took a small rolling pin with
some crisco on it and used a smooth piece of formica counter top underneath
it. It took the edge off of them more than anything. Maybe mine is not as
bad, but like Al said, I don't even notice them anymore.
Mike Betti
Elite 771
----- Original Message -----
From: "Jesse Jenks" <jessejenks@hotmail.com>
To: <rebel-builders@dcsol.com>
Sent: Thursday, September 01, 2005 12:03 AM
Subject: Re: Skin blemishes

Thanks for the replies guys,
I would like to have hope that it would be all OK once riveted in place,
but
I really don't think so. I don't want to cringe every time I look at my
right wing. There is a pattern of small dents about 6" long that repeats
with even spacing for about half the length of the skin. It may be
possible
to burnish them out or something, so I guess I should ask around as you
say.
It looks pretty bad to me though.
The skin is already drilled to #30 along with the ribs, stringers, and
spars. If I started over with a new pre punched skin then would I just
drill
it out to #30 while off the structure and hope the holes line up? I would
be
worried that the holes I already had drilled in the structure might be
slightly misaligned with the new skin because they would have not been
enlarged from #40 to #30 at the same time. That's why I thought it would
be
better to start with a blank sheet and use the original skin as a
template.
Although I would have to drill to #30 on the first go, the holes should be
accurately located by the original skin. Also the holes around the tank
area
where the tank skin joins to the main skin are not pre punched, but where
added by me, and would not be easy to locate without using the original
skin
as a template.
Jesse
From: Jim Cole <jcole@rangroup.com>
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: Re: Skin blemishes
Date: Wed, 31 Aug 2005 22:27:34 -0400

Hi Jesse,

I wanted to extend my tanks to 5 bays from the original 3 bays so I
ordered a new piece of 6061 from a local supplier in Toronto and used
the old skin as a template. They cut it to size and I had a large table
and a piece smooth press board underneath so that I could drill through
with out worrying about it. It worked fine - especially after I bought a
cobalt #40 drill that was sharp and stayed sharp but certainly was time
consuming. I used clecos and clecoed it to the template and the table as
I progress in a sequence from one end to the other.

I'm with Bob though - check with someone with experience locally because
you just might be surprised at what can be done.

Good Luck
Jim (now rebel 333)
Hi Jesse !

Maybe you could find a nearby builder to have a look at that skin -
it might be fixed, or not as bad as you might think ... (optimistically
!)
Perhaps someone from the RAA chapter might have a trick or 2 ...

Hard to imagine that you'd be better off drilling your own - I
think
the CNC punch has a tolerance of less than one thousandth of an inch in
the 12 feet !!
.....bobp

-------------------------------orig.-------------------------
On Wednesday 31 August 2005 09:47 pm, Jesse Jenks wrote:

rolled
half of
I
the LE
it.
to
I
to
off

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Skin blemishes

Posted: Sat Feb 18, 2012 10:59 am
by Jesse Jenks
Ken and Ben,
Thanks for the support. After experimenting on some scrap .020 I convinced
myself that I don't have the skill to remove dents, and ordered a 4X12"
sheet from ACS which should be here tomorrow.
I have 135 degree split point bits as you mention, and I like the idea of
using a paper spacer between the sheets to make sure the bit point is
completely centered in the existing hole. Is corrugated cardboard too thick,
or are you thinking more like card stock? Would you think using an egg cup
would be advisable with a spacer between the sheets, so as to minimize hole
misplacement due to tipping the drill? I am planning to drill through into
the table and cleco right into the table top, or maybe put some plywood on
the table and drill into that. Hopefully I'll be back on track pretty soon.
Thanks for the help.
Jesse

From: bransom@dcsol.com
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: Re: Skin blemishes
Date: Thu, 01 Sep 2005 14:44:08 -0800

I too really like the split point "jobber" bits -- I've gotten mine from
Brown Tool but I'm sure many source the same thing. Cheap enf to toss when
worn out, yet last pretty long since we're on soft aluminum, and they put
holes where you want them more easily than other bits, IMO.
-Ben
Yes I agree. A sheet of thick brown paper between the aluminum sheets if
the top sheet is only 0.020 and a good quality 135 degree split point
bit for the same reason. For large sheets one can put white styrofoam
underneath to keep everything flat as you insert clecos.

Ken

bransom@dcsol.com wrote:
Jesse,
If nothing else, you have my sympathy -- I know that would not make my
day.
Other more experienced than I will certainly know better, but I would
think
that match drilling with #30 to a new sheet, using clecos as you go
would
be
fine. I've done some small parts straight from #30 and wondered if it
would
help to have a small spacer in between so that the full diameter of the
#30
is in the top hole before starting in on the fresh piece underneath,
but
I've
had fine results without this. Again though, this on small pieces
where
if
there was a very slight bit of drill wandering it is unnoticable in
final
product.
Good luck, I'm sure you'll find a good solution.
-Ben




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Skin blemishes

Posted: Sat Feb 18, 2012 10:59 am
by Ken
I think any form of cardboard would be too thick and increase the chance
of misalignment if the bit is not perfectly vertical. Brown wrapping
paper or even a couple of thicknesses of newspaper might be adequate.
I'm thinking 10 or 20 thou if that is card stock.
Ken

Jesse Jenks wrote:
Ken and Ben,
Thanks for the support. After experimenting on some scrap .020 I convinced
myself that I don't have the skill to remove dents, and ordered a 4X12"
sheet from ACS which should be here tomorrow.
I have 135 degree split point bits as you mention, and I like the idea of
using a paper spacer between the sheets to make sure the bit point is
completely centered in the existing hole. Is corrugated cardboard too thick,
or are you thinking more like card stock? Would you think using an egg cup
would be advisable with a spacer between the sheets, so as to minimize hole
misplacement due to tipping the drill? I am planning to drill through into
the table and cleco right into the table top, or maybe put some plywood on
the table and drill into that. Hopefully I'll be back on track pretty soon.
Thanks for the help.
Jesse





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Skin blemishes

Posted: Sat Feb 18, 2012 10:59 am
by Jesse Jenks
Mike,
I am probably being oversensitive, and if it would have been on a top skin I
would probably have used it, but I will try to make a new skin for this one
and try to be more careful in the future. Can you give me any advice on how
to avoid causing the dents? I was thinking about rolling off the plastic on
carpet, do you think that would help? Did you figure out a good way to do
it? My kit has been sitting for a while, and some of the plastic is falling
off on it's own, but some is really stuck on.
Thanks
Jesse

From: "Mike Betti" <mbetti@up.net>
Reply-To: <rebel-builders@dcsol.com>
To: <rebel-builders@dcsol.com>
Subject: Re: Skin blemishes
Date: Thu, 1 Sep 2005 19:37:23 -0500

I had the same problem doing the same thing. I took a small rolling pin
with
some crisco on it and used a smooth piece of formica counter top underneath
it. It took the edge off of them more than anything. Maybe mine is not as
bad, but like Al said, I don't even notice them anymore.
Mike Betti
Elite 771
----- Original Message -----
From: "Jesse Jenks" <jessejenks@hotmail.com>
To: <rebel-builders@dcsol.com>
Sent: Thursday, September 01, 2005 12:03 AM
Subject: Re: Skin blemishes

Thanks for the replies guys,
I would like to have hope that it would be all OK once riveted in place,
but
I really don't think so. I don't want to cringe every time I look at my
right wing. There is a pattern of small dents about 6" long that repeats
with even spacing for about half the length of the skin. It may be
possible
to burnish them out or something, so I guess I should ask around as you
say.
It looks pretty bad to me though.
The skin is already drilled to #30 along with the ribs, stringers, and
spars. If I started over with a new pre punched skin then would I just
drill
it out to #30 while off the structure and hope the holes line up? I
would
be
worried that the holes I already had drilled in the structure might be
slightly misaligned with the new skin because they would have not been
enlarged from #40 to #30 at the same time. That's why I thought it would
be
better to start with a blank sheet and use the original skin as a
template.
Although I would have to drill to #30 on the first go, the holes should
be
accurately located by the original skin. Also the holes around the tank
area
where the tank skin joins to the main skin are not pre punched, but
where
added by me, and would not be easy to locate without using the original
skin
as a template.
Jesse
From: Jim Cole <jcole@rangroup.com>
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: Re: Skin blemishes
Date: Wed, 31 Aug 2005 22:27:34 -0400

Hi Jesse,

I wanted to extend my tanks to 5 bays from the original 3 bays so I
ordered a new piece of 6061 from a local supplier in Toronto and used
the old skin as a template. They cut it to size and I had a large table
and a piece smooth press board underneath so that I could drill through
with out worrying about it. It worked fine - especially after I bought a
cobalt #40 drill that was sharp and stayed sharp but certainly was time
consuming. I used clecos and clecoed it to the template and the table as
I progress in a sequence from one end to the other.

I'm with Bob though - check with someone with experience locally because
you just might be surprised at what can be done.

Good Luck
Jim (now rebel 333)
-
(optimistically
!)
in
rolled half of I the LE
duplicate
it.
right
to I
bushing
to
better
off


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Skin blemishes

Posted: Sat Feb 18, 2012 10:59 am
by Jesse Jenks
Ken,
That's what I thought.
Thanks.
Jesse
From: Ken <klehman@albedo.net>
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: Re: Skin blemishes
Date: Thu, 01 Sep 2005 20:57:32 -0400

I think any form of cardboard would be too thick and increase the chance
of misalignment if the bit is not perfectly vertical. Brown wrapping
paper or even a couple of thicknesses of newspaper might be adequate.
I'm thinking 10 or 20 thou if that is card stock.
Ken

Jesse Jenks wrote:
Ken and Ben,
Thanks for the support. After experimenting on some scrap .020 I
convinced
myself that I don't have the skill to remove dents, and ordered a 4X12"
sheet from ACS which should be here tomorrow.
I have 135 degree split point bits as you mention, and I like the idea of
using a paper spacer between the sheets to make sure the bit point is
completely centered in the existing hole. Is corrugated cardboard too
thick,
or are you thinking more like card stock? Would you think using an egg
cup
would be advisable with a spacer between the sheets, so as to minimize
hole
misplacement due to tipping the drill? I am planning to drill through
into
the table and cleco right into the table top, or maybe put some plywood
on
the table and drill into that. Hopefully I'll be back on track pretty
soon.
Thanks for the help.
Jesse





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Skin blemishes

Posted: Sat Feb 18, 2012 10:59 am
by Mike Kimball
I would find it harder getting the plastic off on a soft surface such as
carpet. Use your table, go slow and careful. Put a lot of pressure on the
uncovered skin with one hand very near to the plastic where you are pulling
on it. Keep the hand that is pulling on the plastic moving to stay close to
the skin. In other words, don't get a hold of the plastic and keep pulling
until your hand is a foot or more from the skin. Pull a couple of inches
then grab again right at the point it's stuck to the skin. Keep the hand
that's on the uncovered skin moving too to stay close to the plastic you are
removing. Don't pull straight up. Pull close to parallel to the skin.
Another thing you can try is to split the width of the plastic you are
removing into strips, say about 12-18 inches wide. Start pulling and when
you get it going, grab the part that is separated from the skin and split it
so you aren't trying to roll off a four foot wide piece. Pull at an angle
on the left side of your strip, then follow with the right side. Keep going
back and forth like that instead of pulling straight down on the strip you
are removing. Hope this helps.

Mike Kimball
044SR

-----Original Message-----
From: mike.davis@dcsol.com [mailto:mike.davis@dcsol.com] On Behalf Of Jesse
Jenks
Sent: Thursday, September 01, 2005 4:53 PM
To: rebel-builders@dcsol.com
Subject: Re: Skin blemishes

Mike,
I am probably being oversensitive, and if it would have been on a top skin I

would probably have used it, but I will try to make a new skin for this one
and try to be more careful in the future. Can you give me any advice on how
to avoid causing the dents? I was thinking about rolling off the plastic on
carpet, do you think that would help? Did you figure out a good way to do
it? My kit has been sitting for a while, and some of the plastic is falling
off on it's own, but some is really stuck on.
Thanks
Jesse

From: "Mike Betti" <mbetti@up.net>
Reply-To: <rebel-builders@dcsol.com>
To: <rebel-builders@dcsol.com>
Subject: Re: Skin blemishes
Date: Thu, 1 Sep 2005 19:37:23 -0500

I had the same problem doing the same thing. I took a small rolling pin
with
some crisco on it and used a smooth piece of formica counter top underneath
it. It took the edge off of them more than anything. Maybe mine is not as
bad, but like Al said, I don't even notice them anymore.
Mike Betti
Elite 771
----- Original Message -----
From: "Jesse Jenks" <jessejenks@hotmail.com>
To: <rebel-builders@dcsol.com>
Sent: Thursday, September 01, 2005 12:03 AM
Subject: Re: Skin blemishes

Thanks for the replies guys,
I would like to have hope that it would be all OK once riveted in place,
but
I really don't think so. I don't want to cringe every time I look at my
right wing. There is a pattern of small dents about 6" long that repeats
with even spacing for about half the length of the skin. It may be
possible
to burnish them out or something, so I guess I should ask around as you
say.
It looks pretty bad to me though.
The skin is already drilled to #30 along with the ribs, stringers, and
spars. If I started over with a new pre punched skin then would I just
drill
it out to #30 while off the structure and hope the holes line up? I
would
be
worried that the holes I already had drilled in the structure might be
slightly misaligned with the new skin because they would have not been
enlarged from #40 to #30 at the same time. That's why I thought it would
be
better to start with a blank sheet and use the original skin as a
template.
Although I would have to drill to #30 on the first go, the holes should
be
accurately located by the original skin. Also the holes around the tank
area
where the tank skin joins to the main skin are not pre punched, but
where
added by me, and would not be easy to locate without using the original
skin
as a template.
Jesse
From: Jim Cole <jcole@rangroup.com>
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: Re: Skin blemishes
Date: Wed, 31 Aug 2005 22:27:34 -0400

Hi Jesse,

I wanted to extend my tanks to 5 bays from the original 3 bays so I
ordered a new piece of 6061 from a local supplier in Toronto and used
the old skin as a template. They cut it to size and I had a large table
and a piece smooth press board underneath so that I could drill through
with out worrying about it. It worked fine - especially after I bought a
cobalt #40 drill that was sharp and stayed sharp but certainly was time
consuming. I used clecos and clecoed it to the template and the table as
I progress in a sequence from one end to the other.

I'm with Bob though - check with someone with experience locally because
you just might be surprised at what can be done.

Good Luck
Jim (now rebel 333)
-
(optimistically
!)
in
rolled half of I the LE
duplicate
it.
right
to I
bushing
to
better
off


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Skin blemishes

Posted: Sat Feb 18, 2012 10:59 am
by bransom
Again, my experience is pretty limited but as I mentioned, match drilling #30
from #30 and I have had no detectable misalignment, even with no spacer.
Another consideration, is that I'd want separator (if any) to be not
squishable (as corrugated cardboard) ...the two skins need to stay parallel
and flat to each other the whole time (curves mean different distances
between points). Try match drilling #30 to #30 on some scrap and see how it
looks.
-Ben
Ken,
That's what I thought.
Thanks.
Jesse
From: Ken <klehman@albedo.net>
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: Re: Skin blemishes
Date: Thu, 01 Sep 2005 20:57:32 -0400

I think any form of cardboard would be too thick and increase the chance
of misalignment if the bit is not perfectly vertical. Brown wrapping
paper or even a couple of thicknesses of newspaper might be adequate.
I'm thinking 10 or 20 thou if that is card stock.
Ken

Jesse Jenks wrote:
Ken and Ben,
Thanks for the support. After experimenting on some scrap .020 I
convinced
myself that I don't have the skill to remove dents, and ordered a 4X12"
sheet from ACS which should be here tomorrow.
I have 135 degree split point bits as you mention, and I like the idea of
using a paper spacer between the sheets to make sure the bit point is
completely centered in the existing hole. Is corrugated cardboard too
thick,
or are you thinking more like card stock? Would you think using an egg
cup
would be advisable with a spacer between the sheets, so as to minimize
hole
misplacement due to tipping the drill? I am planning to drill through
into
the table and cleco right into the table top, or maybe put some plywood
on
the table and drill into that. Hopefully I'll be back on track pretty
soon.
Thanks for the help.
Jesse





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