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Jims RV-8
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Date:  8-26-2015
Number of Hours:  1.00
Manual Reference:  8-44
Brief Description:  Bob Avery drilled the inboard gear holes

I took my gear over to Bob Avery's tool store / shop at Hick's Airfield. If you need some good tools, from a good family operation, the give Avery Tools a click or a call : www.averytools.com (800-652-8379).

I checked with Bob about drilling my gear a few weeks ago when I was in the shop buying some tools. He said he would be happy to drill it...and that I just needed to give him a days notice. Today was the day... I drove over at my lunch break and Bob got right to work. With the punch marks on the "top" side of the gear the natural first hole was thru the top. Bob set up the floor press to drill the first pass holes to a 3/8" hole and then he switched the bit to a 7/16" reamer and finished the hole to a precise fit with the bolt.

Then we went to the milling machine and he set the gear upside down to counter bore the hole to 1" diameter. The counterbore allows the head to recess into the gear since there isn't enough clearance with the thicker gear and the skin that covers the gear. With a "wiggler" in the milling machine, Bob was able to find the center of the 7/16" hole to within 5/10,000th of an inch. So take an inch, cut it in 10,000 equal lengths, and the hole would be off by 5 of those segments!

The counterbore was drilled 3/16" deep and should yield 5/32" clearance between bolt head and skin (minus the washer width)
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drill press drilled to 3/8

drill press drilled to 3/8", then reamed to 7/16"

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flipped over and counter bored

flipped over and counter bored

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Bob Avery making it happen

Bob Avery making it happen

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