Well after a lot of research, I started to countersink my Rudder trailing edge wedge yesterday morning (AEX wedge). I had been struggling with how to reconcile the fact that the hole I drilled through the wedge (and skins) when match drilling was perpendicular to the centerline of the wedge, yet the countersink should be perpendicular to the face of the wedge on each side. If using a pilot cutter in your countersink cage, this will most certaily apply a side load to the little pilot on the countersink cutter. Sure enough, after 10 or so holes, I ended up breaking the pilot off my bit. (#*@&!)
I recalled that on the my practice kit, I countersunk the wedge using a speed deburring tool, which is essentially a countersink cutter with no pilot. Turns out you can create the necessary c'sink with the deburr tool very effectively, if you apply some elbow grease. I then decided to disasseble my c'sink cage and mount the deburring bit in the holder and free hand the process using a drill. If your easy on the trigger and careful (check depth often), you can make great countersinks and my end result was fantastic. I did have to install the wedge into the rudder twice and check for proper nesting of dimples as some needed to go slightly deeper but I was able to finish the job while I wait for a new c'sink cutter to arrive (went with single flute this time).
All this to say, don't be afraid to try something a little different!
I recalled that on the my practice kit, I countersunk the wedge using a speed deburring tool, which is essentially a countersink cutter with no pilot. Turns out you can create the necessary c'sink with the deburr tool very effectively, if you apply some elbow grease. I then decided to disasseble my c'sink cage and mount the deburring bit in the holder and free hand the process using a drill. If your easy on the trigger and careful (check depth often), you can make great countersinks and my end result was fantastic. I did have to install the wedge into the rudder twice and check for proper nesting of dimples as some needed to go slightly deeper but I was able to finish the job while I wait for a new c'sink cutter to arrive (went with single flute this time).
All this to say, don't be afraid to try something a little different!
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