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Larry Winger's 601XL Project
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Date:  11-2-2014
Number of Hours:  2.50
Manual Reference:  
Brief Description:  Enlarged air inlets

One of the things that William Wynne has stressed repeatedly is that the air inlet size should be 4.75 inches. Mine were only 4.5 inches, because that was the inside diameter of the PVC rings I received from Dave Gardea. I was reluctant to try to enlarge the openings out of concern for how I would do it without messing up my previous work. Yesterday I had an idea which proved to work perfectly. I cut out a 4.75 diameter circle from sheet aluminum and used that as my template on the back side of the PVC flange. I was able to center it as much as possible within the available PVC material to leave the maximum thickness in all directions, then I used a thin Sharpie to mark my sanding line. I have an oscillating edge/belt spindle sander that has been one of the most useful tools in my entire project. It came through for me again today. I put on the largest spindle and carefully sanded up to the line all the way around each inlet. Because I was able to lay the face of the nosebowl perfectly flat on the top work surface of the sander, my sanding was all consistently perpendicular, giving a great finished look. If you didn't know, you might think my interior ring was made to be 4.75 inches from the shelf at Home Depot.
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Oscillating Edge/Belt Spindle Sander

Oscillating Edge/Belt Spindle Sander

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Back in business

Back in business

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A closer look

A closer look

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