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Date:  7-8-2008
Number of Hours:  0.00
Manual Reference:  
Brief Description:  Cut out the inspection plate hole.

I used the cheap Harbor Freaight Fly Cutter. This is a piece of crap. I couldn't use the center drill because it was not even close to being straight. And, I didn't use the opposite cutter because it was a different height from the other cutter. But I'm not sure a quality one whould have done better but maybe. Never did get it to go all the way through the rib. Ended up just drilling a small hole in the center and using tin snips to cut it out as best I could. Then used a course drum sander on high speed to finish out the size. Look at the plans closely. They show, in 2 places, that the hole is 1/2" smaller in diameter then the cover plate reinforcement ring. The plans don't tell you the size of hole and I see builder logs making the hole the same size as the reinforcement plate. I compromized and split the difference.
I used the die grinder with a scotch bright wheel to finnish it off.
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Fly cutter attempt.

Fly cutter attempt.

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High speen, course drum sander.

High speen, course drum sander.

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Scotch bright smooth.

Scotch bright smooth.

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