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The Redheads RV-7A Build SIte
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Date:  6-29-2010
Number of Hours:  0.50
Manual Reference:  OP-46 Supplement
Brief Description:  Preparing for the Stall Warning Kit

Only had a hour to spend today so I decided to work on the Stall Warning Kit access hole. I had previously rough cut the hole using my dremel tool with a cut-off wheel but I left 1/4" or more of material to be removed later. Better to remove it slowly than to get carried away with a fast cutting power tool and remove too much. I bought a hack saw handle and a couple of 32 teeth per inch blades (for a smoother and slower cut in aluminum) at my local Ghanal lumber/hardware store. It cantelevers the blade and doesn't have a large frame and fits easily in the hole. Cutting was slow going. The blade doesn't cut fast nor does it turn well so I had a hard time getting my cuts parallel to the desired line. I basically started cutting at a 90 deg angle to the desired cut in the middle of the edge and then came in at progressively shallower angles towards the first cut. After pretty well clearing the bottom half of the cut on the left side it was fairly easy to make the next cut up the same side (Images 1 and 2). After using the hacksaw blade I used my Vixen file to smooth the edges.
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Using a Hacksaw to Rough Cut Access Hole

Using a Hacksaw to Rough Cut Access Hole

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Progress on the Left Side of Access Hole

Progress on the Left Side of Access Hole

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Using Vixen File to Smooth and Straighten Edge

Using Vixen File to Smooth and Straighten Edge

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