Date:	6-12-2011
Number of Hours:	1.00
Brief Description:	Aileron counterweights
Worked on the lead counterweight installation for the ailerons. - Cut the lead counterweights with the band saw. Just go slow and use some Boelube or other blade lubrication. - To hold the lead in place I proped up the aluminum counterballance arms with wood, and duct taped the lead in place - I then drilled through the lead and out the other aluminum leg. Sounds easy, right? On the first hole I was too exuberant, and when the bit got part way through it broke off inside. I had not counted on the lead fouling the bit in quick order, and causing it to bind. I tried to drill out the bit, but there was just no way. - So I instead just went on with the rest of the holes, then later came back and added a new hole to replace the fouled one (see photo #3). The plans call for drilling from both ends, meeting in the middle, and then reaming to size. My experience was that that was severe overkill. I instead went straight through, keeping the drill bit as level and straight as I could by eye. In every case the bit came out the pilot hole on the other side. The "tricks" to getting through were: - I used 3 different bits, going from very thin, to medium to final size. - Use cutting oil on the bit - Go slowly, and pull the bit back frequently to clear the lead from the bit. Sometimes I had to totally back the bit out and clear the lead by hand. - Several times the bit got stuck in the lead. I simply grabbed it with pliers and worked it out. It always came out rather quickly.