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Johns Web Site
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Date: 1-17-2015
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Number of Hours: 7.50
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Manual Reference:
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Brief Description: Right Spar Deburring and Cleanup
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Before the right spar was disassembled, the inboard end of the spar was countersunk for the flathead screws and rivets. The countersink depth is slightly shallower for the bolts than the rivets, so I set up one countersinking tool specifically for bolts and the other for rivets, so once set, they did not need to be readjusted for a different application.
The bolt countersink was adjusted to set the top of the bolt flush, to very slightly below flush. The rivet countersink was adjusted to set the rivet head flush, to 0.005" proud. I wanted to be sure that the rivet squeezer head pushed against the rivet head rather than the spar surface while setting the rivet.
The countersink may not reach the full depth on the first attempt. After the first cut, drop a clean rivet into the hole to see if the head sits at the correct level. Most of the time the countersink will not be deep enough. Use a brush to clean the business end of the tool and cut the hole again. Repeat this process until the rivet sits at the correct level. It normally takes between one-to-four repetitions to get it right. A drop of oil on the guide shank of the cutter every two or three holes also helps.
An inexpensive electric screwdriver with a sharp, three flute deburring tool was used to clean up the edges of drilled or reamed holes. Takes about one-second at each hole with very light pressure.
Several deburring techniques were used for the straight edges of the spar components. The best and fastest tool was a red, three inch, “Rolok” abrasive wheel in a 90-degree, air powered, die grinder. The 3M version of the Rolok disc is expensive, but the Chinese version (Harbor Freight) cost about $1:00 each. These work great for cleaning up hole edges after using the deburring tool, on the edges of the extruded spar angles where there might be small dings that should be removed, on the edges of the 0.032” spar web, and the cut edges of the spar angles to remove the CNC machining marks where the angles are tapered. It is a noisy proc
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Countersinking the Inboard End of the Right Spar
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Cleaning and Deburring
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Cleaning and Smoothing the Beveled Spar Stiffners
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