Well, today was day 1 of vacation-buring-to-work-on-the-Bearhawk. I'm hoping to make up some time that was spent making our yearly video during the first part of December.
I began by finishing the backing rings for the inspection holes. I first rough cut them and then used double sided tape to tape them to the jig. Then I routed them; lots of aluminum dust/shavings!
For the oversized holes, I used the other method of drilling the holes in the corners and using a cutoff wheel to cut out the inside of the ring.
I then remade the inspection hole covers ONE MORE TIME since the last time I made them, it was with .032" aluminum and I needed to use .025" so they sit flush with the skins. I then sanded all the edges on the scotchbright wheel.
Finally, I marked all the locations for the holes, took a deep breath, measured one more time, and drilled the holes for the first inspection hole on the left wing. It turned out great. WHEW!
