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Terrences Web Site
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Date: 3-18-2008
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Number of Hours: 2.00
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Manual Reference: 6LLO-1
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Brief Description: Put lightening holes in landing light channels
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1. Replaced the drill bit in the fly cutter with a 1/4" smooth shaft (actually a 1/4 x 20 bolt with the hex head and threads cut off). This mod was suggested by someone on a Van's forum.
2. Cut a piece of 3/4" plywood so that it would fit between the top and bottom flanges of the channel.
3. Used the drill press to drill a 1/4" hole through the plywood, and through the center of the web on each channel.
4. Clamped the plywood to the "super, incredible Workmate," clamped a channel to the plywood with the holes aligned, and inserted the fly cutter shaft into the hole. See Fig. 1.
5. Turned the flycutter by hand to cut ~half way through the web.
6. Turned the channel over and cut as deeply as possible from the other side, Eventually, the cutter hangs up in spots where it penetrates to the wood.
7. Remove the channel from the clamps, place the channel on the edge of the Workmate, and push the disk out of the hole, using the Workmate to support the web while pushing on the disk.
8. Use Randy Thwing's 65-mm flanging die and his "auto-press" to press the flanges into the lightening holes. Thank you Randy! See Fig. 2.
9. Flanged products, see Fig. 3.
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Fly cutter setup
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Hole flange press
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Finished light channels
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