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Date:  12-6-2014
Number of Hours:  12.00
Manual Reference:  
Brief Description:  Pre assembly of elevators

I started pre-assembly of the elevators with deburring of the ribs....

Deburring is certianly not my favorite. I have been looking for a method or tool that will both do a good job and be easy to do on edges. Hand tools such as scrapers and files work, but are tedious and marginally effective. I purchased a round abrasive ball thingy. That, in an electric die grinder is great for broad surface prep, quick and efficient. However on edge deburring it is not so good. It tends to grab the part and throw it across the room, as well as getting everything else along with the burr. (It does work great on lightning holes by pushing the top directly against the raised edge)
I found a 2" scotch brite wheel in a 90 degree pnuematic HF die grinder is fantastic on edges. Quick, easy to control and effective. (not to mention inexpensive) This will be the go to tool from here on.

I also made up a set of fluting pliers from a pair of $3 vise grips. I TIG welded 3 1/8" dowel pins to the jaws. Two on one side and one in the center to the other side. A little polishing with the 2"scotchbrite, and a very functional pair of fluting pliers in about 5 mins.

Most of the pre-assembly is done in the pics below. I have all 350 recomended 3/32" clecos in use and could use 200 more. I have to take from one side to get enough to drilll the other side. It makes for a lot of unnecessary cleco moving. I have another 100 on order and will likely order at least another 100. I cleco every other hole for drilling, mark drilled holes with a sharpie, then move each cleco 1 hole. That way in 2 goes, all of the holes on each side are match drilled.
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match drilling

match drilling

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add trim cable exit plates

add trim cable exit plates

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