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Old 09-09-2018, 09:18 AM
OrenAir OrenAir is offline
Join Date: Jan 2017
Location: Chantilly, VA
Posts: 86
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, 09:21 AM
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Mel Mel is online now
Join Date: Mar 2005
Location: Dallas area
Posts: 10,149

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..DAR since last century
A&P/EAA Tech Counselor/Flight Advisor/Nat'l Test Pilot School
Specializing in Amateur-Built and Light-Sport Aircraft
North Texas (8TA5)
RV-6 Flying since 1993, 172hp O-320, 3-Blade Catto (since 2003)
Legend Cub purchased 12/2017
FRIEND of the RV-1
Eagle's Nest Mentor
Recipient of Wright Brothers "Master Pilot" Award
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Old 09-09-2018, 09:45 AM
coffeeguy coffeeguy is offline
Join Date: Jul 2015
Location: Lake in the Hills, IL
Posts: 106

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
Cherokee 180
2018 dues paid
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Old 09-09-2018, 09:48 AM
azflyer21 azflyer21 is offline
Join Date: Nov 2016
Location: Scottsdale AZ
Posts: 105

I used my hand deburring tool for these. You will find other areas where this tool will work nicely for the countersink.
Kevin Lippert
Zenith 750 completed 2016 -

N1402 reserved
RV-14a Empennage Done
QB Wing QB Fuse inprogress
Build Log
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Old 09-10-2018, 08:00 PM
Stockmanreef Stockmanreef is offline
Join Date: Nov 2012
Location: Midland, mi
Posts: 601

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

RV-14 (serial number 140073)
N73XP (at least that # reserved now)
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Old 09-11-2018, 07:53 AM
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bkervaski bkervaski is offline
Join Date: Mar 2017
Location: Birmingham, Alabama
Posts: 851

+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.
#140376 RV-14A QB IO-390 Thunderbolt
Registered: N196
Progress: Flying!
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Old 09-11-2018, 08:24 AM
BillL BillL is offline
Join Date: Sep 2007
Location: Central IL
Posts: 4,553

Hand deburring like the crowd. But this might be a good time to get a 1/4" shaft single hole deburring tool. You can use it on the plexiglass later. It will leave a nice smooth, concentric CS.

1st Flight 1-27-18
Phase II 8-3-18
Repairman 11-15-18
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Old 09-11-2018, 08:25 AM
Mudfly Mudfly is offline
Join Date: Dec 2011
Location: Alpharetta, Ga
Posts: 152

I use a variable speed drill and a countersink bit for almost all my countersinking needs. I keep the drill speed very slow and just keep checking for correct depth with a rivet. After several, I normally can get the proper depth after a couple checks.

Shawn Edwards
RV-14A (140174)
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Old 09-13-2018, 04:33 PM
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Erimo Erimo is offline
Join Date: Jul 2015
Location: Marcoussis, France
Posts: 74

Originally Posted by Mel View Post
Most people obtain a second cage and cut away one side.
Another option is to remove the cage and carefully "freehand" the countersink.
I countersunk witout cage. Well.
RV 14A - #140252 - Flying
2018 dues paid
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