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Debo Cox - Zodiac 601 XL
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Date:  6-17-2007
Number of Hours:  1.50
Manual Reference:  6W
Brief Description:  #4 Ribs Complete

It occurred to me today that I haven't detailed how I cut lightening holes in my ribs and wherever else they're called for. I use holes saws pretty much exclusively. With my apologies to fly-cutter enthusiasts, I found that thing to be inaccurate, dangerous, and one step away from a trip to the emergency room. I know a lot depends on the operator, but I just didn't like it. I find that hole saws do an excellent job of cutting a nice, round hole in almost any thickness stock. Here are the drawbacks. 1.) You need to proceed slowly. Let the tool do it's work and nibble away little bits of aluminum at a time. Don't get in a hurry. A squirt or two of your favorite light lube (no comments here) can help alleviate any grabbing tendancies. 2.) As you penetrate the material, the saw will have a tendancy to grab - spinning the drill out of your hands if you're not careful. See #1. 3.) They're comparatively expensive, but infinitely reusable, and as we all know you can't have too many tools. Oh yeah, I finished my #4 ribs too. On to #5. One more rib and I'll be halfway done! They look great. I'm pleased. I just checked my log, and each set of ribs is taking about 5 hours. That's including fabricating the blocks. Wow. That means I'll have about 45 hours in rib fabrication when it's all said and done.
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Rib clamped down for hole-cutting

Rib clamped down for hole-cutting

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95mm hole saw on my Makita 1/2

95mm hole saw on my Makita 1/2" drill

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Finished #4 ribs

Finished #4 ribs

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