Monday, May 23, 2005

Wing 3, Drilling holes in new spars

Photo of drill press set up to drill holes in spars.

I mounted my benchtop dirll press on the rolling cart that normally supports my sandblaster.  The old spar was clamped on top of the new spar blank with the butt ends perfectly aligned.  Then it was a simple matter to drill through the old spar holes into and through the new spar.  The drill press assures that the holes are perfectly straight and true and perpendicular to the face of the spar.

One little trick: the oldspar/newspar sandwich should NOT be clamped to the drill press table.  If the sandwich is loosely set on the drill  press, it is allowed to "float" as the drill bit enters the old spar hole and any misalignment will be eliminated as the spar sandwich is able to move to align itself with the drill.  Another tip is to use a scrap piece of wood under the spar sandwich so the drill bit does not burst through the wood as it exits.  That way you get a nice clean hole on both sides of the spar.

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