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Old 04-02-2018, 12:29 PM
BillL BillL is offline
Join Date: Sep 2007
Location: Central IL
Posts: 4,359

Originally Posted by Mark Dickens View Post
I just take my hand drill and very carefully drill a #40 pilot hole on one side. Then put it in the jig and drill it through to the other side with the drill press. It's always worked for me.
Yep, and look through the end to visually align through the center, the curve will do the rest.

It is the location on the opposite side that makes it a diametrical hole.

1st Flight 1-27-18
Aerobatics done
Phase II 8-3-18
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Old 04-02-2018, 12:46 PM
PilotjohnS PilotjohnS is offline
Join Date: Jan 2016
Location: Los Angeles
Posts: 497
Default gave up on rivets

I gave up on the rivets and welded mine. For my 9, the rivets touched the rear spar at the extreme ends of travel and I didn't like that. YMMV
John S

WARNING! Information presented in this post is my opinion. All users of info have sole responsibility for determining accuracy or suitability for their use.

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RV9A- Status: tail feathers done less tips
Wings done less tips and avionics
Fuselage 30%
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Old 04-02-2018, 12:54 PM
Pixair Pixair is offline
Join Date: Jul 2017
Location: Napa Valley
Posts: 12
Default Drilling hole in round tube

Might try a "center drill" into punch mark to get hole started. Or I often use a small end cutting end mill instead of drill bit.

Set up will need to be as rigid as possible for the milling cutter and with a slow feed rate into material. Not something you can "hand hold."

A milling machine is preferred, but small end cutters will work in a drill press as long as there isn't much play in the spindle.

Can probably get the above bits at a local machine tool supply store (if you have one in your area) or Amazon or MSC on line.
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Old 04-02-2018, 01:09 PM
nilberg nilberg is offline
Join Date: Dec 2012
Location: Katy, TX
Posts: 151

I would use this:

Instead of clamping, firmly duck tape the v guide to the tube and use a hand drill. I used that on the tip-up release mechanism tubes and those are even smaller diameter than the aileron push rids. .
Bjorn N - RV 7 in progress
Katy, TX
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Old 04-02-2018, 01:55 PM
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bkervaski bkervaski is offline
Join Date: Mar 2017
Location: Birmingham, Alabama
Posts: 737

I got them done by carefully drilling a tiny pilot hole with a hand drill and then using the drill press to finish. The fully drilled through pilot hole was enough to keep everything on track.

I like the welding idea lol
#140376 RV-14A QB IO-390 Thunderbolt
Registered: N196
Progress: Flying!
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Old 04-02-2018, 02:38 PM
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9GT 9GT is offline
Join Date: Jan 2010
Location: Southern Michigan
Posts: 1,447

Center drills work wonders for stuff like this. And don't buy the cheap China crappy ones!
David C.
Howell, MI

RV-9A: Under Construction. N161RV (Reserved)
RV-10: N959RV Completed 12/29/2013 SOLD 08/23/2016

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Old 04-02-2018, 03:42 PM
Taltruda Taltruda is offline
Join Date: Oct 2017
Location: Las Vegas, NV
Posts: 77
Default Holes on tube

I have had luck drilling holes on tube by filing a flat into it first, then center punch the flat, and drill. Just keep the flat area smaller then the hole so that when you upsize the hole, the flat disappears.
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Old 04-02-2018, 09:23 PM
sf3543 sf3543 is offline
Join Date: Jan 2005
Location: San Antonio, TX
Posts: 908

If you are still having trouble drilling those i have two suggestions you can try
Make sure the v block is in exactly the right place by putting the drill bit down all the way to verify it is touching the center of the v to insure it is perpendicular.
Also, You can make a saddle out of a piece of scrap tubing with a drilled hole in it. Place the saddle on the tube with the hole over the spot you want to drill and it will keep your bit from wandering. You can clamp the saddle on or make it big enough to just hold it in place till you get the bit started
Steve Formhals
RV6, RV8 (2), RV12 & RV3 99% done.
A&P, Tech Counselor & Flight Advisor
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Old 04-03-2018, 06:02 AM
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DanH DanH is online now
Join Date: Oct 2005
Location: 08A
Posts: 7,736

Make a tool...

Dan Horton
Barrett IO-390
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Old 04-03-2018, 07:22 AM
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bkervaski bkervaski is offline
Join Date: Mar 2017
Location: Birmingham, Alabama
Posts: 737

I got mine drilled using a pilot hole instead of a punch .. but keep the suggestions coming this is all great stuff!!!
#140376 RV-14A QB IO-390 Thunderbolt
Registered: N196
Progress: Flying!
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