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Bill's Glasair Odyssey
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Date:  7-13-2007
Number of Hours:  1.50
Manual Reference:  Step B-3
Brief Description:  Belly Pan Hinges - Drilled Rivet Holes

Stop the presses! I actually accomplished something on this project. There are two piano hinges used to attach the belly pan to the fuselage. There are about eighty holes to drill in the hinge halves. Rather than mark and centerpunch each hole I decided to make a simple drill fixture. Overkill maybe! The fixture took me about an hour to make (lunch hour). I was then able to drill all the holes on the mill in about twenty minutes. The drill fixture locates the outside edge of the flange and the hinge pin finger. The fixture is just a piece of aluminum bar with a milled step in it. Two pins (cut off nails) stradle the hinge pin finger. The fixture positively locates the hinge and results in a hole perfectly centered on each finger at a perfect distance from the flange edge. Worked great! This little fixture will also work on the dirll press in the hanger allowing me to drill the flap and aileron hinges. The distance to the edge on the other hinges is determined on final fitting and is determined by skin thickness and reinforcement locations. See pictures of jig. The fixture is secured in the mill vise and presto, perfect holes.
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Top View of Fixture with Pins

Top View of Fixture with Pins

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End View Showing Step

End View Showing Step

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Hinge loaded into fixture

Hinge loaded into fixture

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