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Michaels Web Site
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Date: 6-12-2011
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Number of Hours: 1.00
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Manual Reference:
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Brief Description: Aileron counterweights
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Worked on the lead counterweight installation for the ailerons.
- Cut the lead counterweights with the band saw. Just go slow and use some Boelube or other blade lubrication.
- To hold the lead in place I proped up the aluminum counterballance arms with wood, and duct taped the lead in place
- I then drilled through the lead and out the other aluminum leg. Sounds easy, right?
On the first hole I was too exuberant, and when the bit got part way through it broke off inside. I had not counted on the lead fouling the bit in quick order, and causing it to bind. I tried to drill out the bit, but there was just no way.
- So I instead just went on with the rest of the holes, then later came back and added a new hole to replace the fouled one (see photo #3).
The plans call for drilling from both ends, meeting in the middle, and then reaming to size. My experience was that that was severe overkill. I instead went straight through, keeping the drill bit as level and straight as I could by eye. In every case the bit came out the pilot hole on the other side.
The "tricks" to getting through were:
- I used 3 different bits, going from very thin, to medium to final size.
- Use cutting oil on the bit
- Go slowly, and pull the bit back frequently to clear the lead from the bit. Sometimes I had to totally back the bit out and clear the lead by hand.
- Several times the bit got stuck in the lead. I simply grabbed it with pliers and worked it out. It always came out rather quickly.
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Cutting the lead counterweights with the band saw
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To hold the lead in place I proped up with wood, & duct taped in place
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Counterweight bolted in place (note bad pilot hole)
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