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Old 09-09-2018, 08:18 AM
OrenAir OrenAir is offline
Join Date: Jan 2017
Location: Chantilly, VA
Posts: 93
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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Old 09-09-2018, 08:21 AM
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Mel Mel is online now
Join Date: Mar 2005
Location: Dallas area
Posts: 10,570

Most people obtain a second cage and cut away one side.
Another option is to remove the cage and carefully "freehand" the countersink.
Mel Asberry
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Old 09-09-2018, 08:45 AM
coffeeguy coffeeguy is offline
Join Date: Jul 2015
Location: Lake in the Hills, IL
Posts: 148

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.
Jeff Dingbaum
RV-14A empennage, wings, fuselage
Cherokee 180
2019 dues paid
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Old 09-09-2018, 08:48 AM
azflyer21 azflyer21 is offline
Join Date: Nov 2016
Location: Scottsdale AZ
Posts: 224

I used my hand deburring tool for these. You will find other areas where this tool will work nicely for the countersink.
Kevin Lippert
RV-14A N1402 Flying 03-2020
Build Log
Zenith 750 completed 2016 -
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Old 09-10-2018, 07:00 PM
Stockmanreef Stockmanreef is offline
Join Date: Nov 2012
Location: Midland, mi
Posts: 914

+1 to hand deburring
Ken Stockman
Midland, MI
EAA Chapter 1093 member

FaceBook Page: Ken's RV-14
RV-14a (serial number 140073)
N73XP (at least that # reserved now)

Working on the baffles and exhaust
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Old 09-11-2018, 06:53 AM
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bkervaski bkervaski is offline
Join Date: Mar 2017
Location: Birmingham, Alabama
Posts: 1,473

+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.
RV-14A #140376
N196 (Flying)
2019 Bronze Lindy
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Old 01-15-2019, 09:34 PM
MonkeyWrench MonkeyWrench is offline
Join Date: Mar 2018
Location: VA
Posts: 11

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.
working on empennage
EAA Chapter 186
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Old 01-15-2019, 10:39 PM
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wjb wjb is offline
Join Date: Nov 2012
Location: Half Moon Bay, CA
Posts: 971

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.
Bill Bencze
N430WB RV-7 #74152, tip-up; IO-360; CS. Pushing toward first flight in 2020!

Log at:
Defeating gravity one rivet at a time
VAF 2020 donation happily made
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Old 01-16-2019, 11:23 AM
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bk1bennett bk1bennett is offline
Join Date: Nov 2015
Location: Sachse, TX
Posts: 64

I used a drill press and my calibrated eyeball.
Latest Annual Donation Date: 20 Aug 2019
RV-14A Empennage Kit #140396
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Old 01-16-2019, 05:05 PM
RV10Pilot RV10Pilot is offline
Join Date: Jan 2005
Location: Medford, NJ USA
Posts: 259

How about something like this
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