[rebel-builders] final drilling wing bolts

[Drew Dalgleish]

Hi Jesse I think that trying to do it all at once is only worthwhile if
you're trying to straighten out a misalignment. If everything was good the
first time you had it together then it should all line up if you drill or
ream each piece seperately.

At 07:46 PM 8/19/2007 -0700, you wrote:
[quote]I have had my wings on temporarily once to get everything aligned and build
the struts. I used undersized bolts, and planned to drill everything to
final size at a later date. Now I am wondering if I should reassemble and
drill the fittings while mated to ensure proper bolt to hole alignment, or
if I can drill/ream everything separately. Doing it assembled sounds better,
but I don't know how I would keep everything from moving while drilling. For
example, if I remove the bolt from the front wing attachment then how do I
immobilize that joint while drilling? There is a large gap between the
fittings, and so no way to clamp them tight. The rear fitting and the struts
may be easier because they all have a close fit, but still seems a bit harry
trying to keep it together with no bolts.
Thanks
Jesse

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[Jesse Jenks]

Thanks Drew,
That makes sense to me.
Jesse

From: Drew Dalgleish <drewjan@cabletv.on.ca>
Reply-To: <rebel-builders@dcsol.com>
To: <rebel-builders@dcsol.com>
Subject: Re: [rebel-builders] final drilling wing bolts
Date: Sun, 19 Aug 2007 22:57:56 -0400

Hi Jesse I think that trying to do it all at once is only worthwhile if
you're trying to straighten out a misalignment. If everything was good the
first time you had it together then it should all line up if you drill or
ream each piece seperately.

At 07:46 PM 8/19/2007 -0700, you wrote:

I have had my wings on temporarily once to get everything aligned and

build

the struts. I used undersized bolts, and planned to drill everything to
final size at a later date. Now I am wondering if I should reassemble and
drill the fittings while mated to ensure proper bolt to hole alignment,

or

if I can drill/ream everything separately. Doing it assembled sounds

better,

but I don't know how I would keep everything from moving while drilling.

For

example, if I remove the bolt from the front wing attachment then how do

I

immobilize that joint while drilling? There is a large gap between the
fittings, and so no way to clamp them tight. The rear fitting and the

struts

may be easier because they all have a close fit, but still seems a bit

harry

trying to keep it together with no bolts.
Thanks
Jesse

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[bransom]

I would think so too, although I'm stating from experience with another
plane, not a Rebel. It just seems that if you're careful about stepping up
drill sizes and then reaming, the holes will be in the same place as when
you did alignment. Otherwise, trying to get a drill motor to the right
location and angle on an assembled part is sometimes difficult, or pushing
on the drill can nudge the assembly, or the problems you mentioned of
having to pull out the bolt that holds alignment, to drill without changing
alignment.
-Ben/ 496R

Hi Jesse I think that trying to do it all at once is only worthwhile if
you're trying to straighten out a misalignment. If everything was good the
first time you had it together then it should all line up if you drill or
ream each piece seperately.

At 07:46 PM 8/19/2007 -0700, you wrote:

I have had my wings on temporarily once to get everything aligned and build
the struts. I used undersized bolts, and planned to drill everything to
final size at a later date. Now I am wondering if I should reassemble and
drill the fittings while mated to ensure proper bolt to hole alignment, or
if I can drill/ream everything separately. Doing it assembled sounds

better,

but I don't know how I would keep everything from moving while drilling.

For

example, if I remove the bolt from the front wing attachment then how do I
immobilize that joint while drilling? There is a large gap between the
fittings, and so no way to clamp them tight. The rear fitting and the

struts

may be easier because they all have a close fit, but still seems a bit

harry

trying to keep it together with no bolts.
Thanks
Jesse

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[Ken]

As other have said take it apart to ream or you will likely get oval holes.
Suggest you test your bolts in a practice hole first.
At least a thou undersize reamer with precision AN174 bolts, several
thou under for AN4.
My best fit was 2 and a half thou undersize for AN6. I don't think
precision bolts are easilly available in this size so you don't get to
use that trick if the holes are too large.
Ken

Jesse Jenks wrote:

I have had my wings on temporarily once to get everything aligned and build
the struts. I used undersized bolts, and planned to drill everything to
final size at a later date. Now I am wondering if I should reassemble and
drill the fittings while mated to ensure proper bolt to hole alignment, or
if I can drill/ream everything separately. Doing it assembled sounds better,
but I don't know how I would keep everything from moving while drilling. For
example, if I remove the bolt from the front wing attachment then how do I
immobilize that joint while drilling? There is a large gap between the
fittings, and so no way to clamp them tight. The rear fitting and the struts
may be easier because they all have a close fit, but still seems a bit harry
trying to keep it together with no bolts.
Thanks
Jesse

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[Jesse Jenks]

Thanks Ken,
How much of an interference fit are you looking for? 2.5 thou seems like a
lot. Are you having to really pound the bolt in?
Jesse

From: Ken <klehman@albedo.net>
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: Re: [rebel-builders] final drilling wing bolts
Date: Mon, 20 Aug 2007 21:56:28 -0400

As other have said take it apart to ream or you will likely get oval holes.
Suggest you test your bolts in a practice hole first.
At least a thou undersize reamer with precision AN174 bolts, several
thou under for AN4.
My best fit was 2 and a half thou undersize for AN6. I don't think
precision bolts are easilly available in this size so you don't get to
use that trick if the holes are too large.
Ken

Jesse Jenks wrote:

I have had my wings on temporarily once to get everything aligned and

build

the struts. I used undersized bolts, and planned to drill everything to
final size at a later date. Now I am wondering if I should reassemble and
drill the fittings while mated to ensure proper bolt to hole alignment,

or

if I can drill/ream everything separately. Doing it assembled sounds

better,

but I don't know how I would keep everything from moving while drilling.

For

example, if I remove the bolt from the front wing attachment then how do

I

immobilize that joint while drilling? There is a large gap between the
fittings, and so no way to clamp them tight. The rear fitting and the

struts

may be easier because they all have a close fit, but still seems a bit

harry

trying to keep it together with no bolts.
Thanks
Jesse

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[Ken]

Hi Jesse
2.5 under lets you push it in with your thumb.
All the AN bolts are several thou undersized. Different lots will vary
several thou as well. I just don't like sloppy strut bolts etc.
Bob had the forward stab mount bolts loosen off once which I assume was
because of play in the strut bolts letting the stab flap up and down a
wee bit...
Ken

Jesse Jenks wrote:

Thanks Ken,
How much of an interference fit are you looking for? 2.5 thou seems like a
lot. Are you having to really pound the bolt in?
Jesse

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