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  #1  
Old 09-09-2018, 08:18 AM
OrenAir OrenAir is offline
 
Join Date: Jan 2017
Location: Chantilly, VA
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Default No room for the countersink cage

I'm supposed to countersink #30 the rudder stops, although there's no way the cage can fit inside that angle. How do you do this step?
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  #2  
Old 09-09-2018, 08:21 AM
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Mel Mel is online now
 
Join Date: Mar 2005
Location: Dallas area
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Most people obtain a second cage and cut away one side.
Another option is to remove the cage and carefully "freehand" the countersink.
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Old 09-09-2018, 08:45 AM
coffeeguy coffeeguy is offline
 
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Location: Lake in the Hills, IL
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Everyone has that problem. You have decide what is right for you. I think I wound up taking the CS bit and putting it on my deburring tool and hand cranking that. Not show quality, but certainly acceptable. Those rivets were a little difficult to set too, can't get the head of your flush mount rivet set in there. I wound up using a flat piece of steel and using that between the rivet and the flush mount rivet set.
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Jeff Dingbaum
RV-14A empennage, wings, fuselage
Cherokee 180
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  #4  
Old 09-09-2018, 08:48 AM
azflyer21 azflyer21 is offline
 
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Location: Scottsdale AZ
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I used my hand deburring tool for these. You will find other areas where this tool will work nicely for the countersink.
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  #5  
Old 09-10-2018, 07:00 PM
Stockmanreef Stockmanreef is offline
 
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Location: Midland, mi
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+1 to hand deburring
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Midland, MI
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  #6  
Old 09-11-2018, 06:53 AM
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bkervaski bkervaski is offline
 
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Location: Birmingham, Alabama
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+2 to hand deburring tool ... once I got some practice I found myself going for this tool vs the drill and cage as it was more convenient, especially on fiberglass.
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  #7  
Old 01-15-2019, 09:34 PM
MonkeyWrench MonkeyWrench is offline
 
Join Date: Mar 2018
Location: VA
Posts: 11
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Wish I saw this a few days ago. I figured out how to CS by hand with a deburring tool. Came out ok. Happy to say, i use a cage on all my other CS work.

One quick note, If you use a back rivet set on the manurfactured head of that rivet, use electrical tape on the manufactured head and push real hard. Or, your manufactured head will bulge up.
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RV-14A
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  #8  
Old 01-15-2019, 10:39 PM
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wjb wjb is offline
 
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Location: Half Moon Bay, CA
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I've been hand drilling the countersinks in my cowl using some carbide-burr countersink bits with great results. Go slow, and check often. All have come out just right.
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N430WB RV-7 #74152, tip-up; IO-360; CS. Pushing toward first flight in 2020!

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  #9  
Old 01-16-2019, 11:23 AM
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bk1bennett bk1bennett is offline
 
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Location: Sachse, TX
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I used a drill press and my calibrated eyeball.
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  #10  
Old 01-16-2019, 05:05 PM
RV10Pilot RV10Pilot is offline
 
Join Date: Jan 2005
Location: Medford, NJ USA
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How about something like this
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