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Kurt Haller RV-9A
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Date: 3-16-2011
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Number of Hours: 1.70
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Manual Reference: 8
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Brief Description: Spar center section
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Bought 3/8" Al rod from Workbench Hardware to fill in the misdrilled hole on F-633-R. Since original hole was off center, can't use a concentric bushing. I threaded the rod with 3/8-24 die, drilled out the hole to 21/64ths, and tapped it 3/8-24. Screwed in the rod, blue gel threadlocker on the threads, up to the shoulder were the die stop cutting and snugged it up with a vise-grip on the unthreaded part of the rod. Sawed off the excess, then filed, sanded, polished flush.
HOWEVER...I opened up the misdrilled bottom hole in 1/64th increments. Don't have 21/64ths reamer, so started with a reamed 0.2490 hole and figured the hole would be a bit less eccentric by taking 1/128th shavings stepwise up to 21/64ths. In the process of doing this, I evidently drilled the TOP HOLE with the 5/16th's drill.
Oy gewalt! That explains why 1/128th seemed like more on two of the steps!! Now need to find or make a 5/16 OD, 3/16 ID plain bushing. (Or go buy the $28 replacement part...or figure how to press out the bearing and reinstall in a freshly fabricated bracket.... :(
Called it a night after this screw up for sure!
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