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Alaskan Bearhawk
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Date: 12-11-2013
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Number of Hours: 2.50
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Manual Reference:
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Brief Description: Flap Handle Part 1
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Ok, this has to be one of the challenges on this build to do without special tools. Drilling the hole, an accurate hole, for the 3/8ths bushing for the flap quadrant was tough! I suppose it would be ok to drill a smaller hole into the side of the tube from each side and work it with a file, but that is a LOT of work. I’ve tried it in the past and it’s not fun!
I have all these fancy tools I’ve accumulated, so it’s time to put them to work. I have a Drill-Rite drill guide that is made for this, but the problem is sneaking around that diagonal tube in the way for a straight shot. Once I measured the location of the hole I made sure the drill guide was at 90 degrees to the tube using two digital levels. Once that was done, I used once of my fancy surplus angle drills. I started out with a 3/16ths bit, then went to a 1/4in bit. The final hole is 3/8ths and I don’t have a short bit that would work. I thought about it for quite a while, but then I remembered I bought a set of threaded drill collets that accept normal bits from Brown Tool Supply. I took a normal 3/8ths bit, cut it in half and reground the tip on my grinder. I turned the shank down to 1/4in on the lathe and I was in business! It took some time, but the result was a clean hole in the right spot. Before I did anything else, I took a small magnet that people use to check for bondo on cars and got all the metal shavings I could out of the hole. On to the flap mount.
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Sneaking in
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Custom 3/8ths bit
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Bushing in place
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