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Today was a quick work session but a harrowing one. Nothing real dangerous or difficult, just scary. I made the pitot cutout in the left wing outboard bottom skin. Like I said, not too difficult, but it always raises a few goosebumps to cut holes in a perfectly good and expensive piece of aluminum. I made this by first drilling three pilot holes and then enlarging them with the uni-bit. Then I took the hole to within about 1/32" of its final size with the milling bit in the Dremel. This was nice because it cuts through the aluminum like butter. This was also scary because it cuts through the aluminum like butter. The trick was to just go very slowly and use only the lightest pressure so as to not gouge a big chunk out of the skin. When I got it very close to final size, I switched to the sanding drum in the Dremel as well as a hand file on the skinny end.  Overall the fit is excellent with about 1/32" gap all the way around. If there was a way to get a more snug fit I don't know of it. Also, I don't know why I could even want a more snug fit so I'm satisfied with this. You may notice that back plate on the pitot mast slightly covers a fourth hole on its bottom right corner. I will probably cut off the bottom right corner of the backing plate to get rid of the interference here. 
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| Thanks for visiting! | Last Update: 25 May 2012 |