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Michaels Web Site
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Date: 7-7-2012
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Number of Hours: 2.00
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Manual Reference: L01
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Brief Description: Drilling gear legs
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- Hung the engine mount temporarily to see if there was any interference with the titanium gear legs. There was some on the right side, but a few minutes with the Dremel cleared that up.
- In photo #1 you can see that, like most builders, I found the lowest engine mount screws to be too long. They bump into the diagonal tube inside. So I will have to order some MS24694-S96 screws, which should fit.
- Then I put the gear legs into their supporting tubes and aligned the 34" marks that I put on the legs (they came just a tad longer). Now I stuck a drill bit (chucked in the drill) down the bolt hole/tube to mark that location on the gear leg.
- Took the left gear leg out, put it on my pipe centering drill jig, and SLOWLY drilled the 1/4" hole (no pilot holes; just 1/4" straight through) using the slowest speed of my drill press, with a cobalt 1/4" bit, and using LOTS of cutting fluid. Used light pressure and backed the drill bit out often to clear the shavings and to let the materials cool. There really is no reason to drill pilot holes using this method, and Sonex does not recommend using pilot bits. I ended up with a very tight fit bolt hole.
- I then put the leg back into the engine mount and put a 1/4" bit through the engine mount hole/tube, and the gear leg, until the bit touched the opposite side of the steel engine mount tube that holds the gear. That put a mark on the inside wall of the tube.
- I then backed out the drill bit, took the gear leg out, and then inserted a 6" long, 1/8" drill bit to make a pilot hole in the back side of the tube, using the mark I had just made to set the bit.
- After making the pilot hole I put the 1/4" bit back in and made the final hole.
- Deburred everything.
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Engine mount on, and landing gear legs in place for marking.
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Lowest screws between motor mounts and engine mount, are too long; they bump the diagonal tube inside.
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Drilling the first gear leg
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