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Thatcher CX-5 Build Log
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Date: 6-25-2018
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Number of Hours: 14.00
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Manual Reference:
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Brief Description: Bulkheads F2 and F4
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Somewhat obviously, this is 14 hours over the course of the weekend. I cut the MDF formers for bulkheads F2 and F4, and attached 1:1 drawings of the bulkheads to the appropriate 6061 sheets. The bulkheads were cut out, then the control pass throughs were cut out. The first F2 bulkhead had the pass-though cut out by drilling a series of 3/32" holes around the perimeter of the cut-out, then cutting away the pass through. This yielded an incredible amount of grinding to get a finished surface. Hours later, I decided to not use that technique again.
The second F2 bulkhead, I decided to use a Dremel with a cut-off wheel. This was slighly better, but consumed a rediculous number of cut-off wheels.
The F4 bulkheads were cut out with step-bits, and the Dremel used to releive the straight cuts between the drilled holes. This is, apparently, the right way to cut out those losenge shaped holes. This took about one-quarter the time, and one-eighth the number of cut-off wheels.
The only flaws in the plan werea couple of minor cuts on my fingers from the bulkhead spinning when the step bit caught. I had it clamped down, but I only used one clamp and neglected to wear my gloves. Note to my future self; always wear gloves when working with the step bit, and always clamp the bukhead in TWO places.
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