John DiStefano Posted February 16, 2006 Share Posted February 16, 2006 OK, here's what I did. I drilled the #21 holes into the aluminum slugs.. 15 out of 16 came out real nice. One needs repair, only about 1/2 the diameter of the drilled hole is in the slug. But here is ther real issue. I read the directions wrong, followed them too literally w/out paying attention, I proceded to opening the slugs AND the gear cover with a # 11 drill bit. So, now, of course the tap does absolutely nothing and the S50 screws just drop in. Not good. So, how to fix. A- Should I go with the next largest Diameter Machine screw? Which would be 1/4" X 28 I think. B- Flox and re-tap the per the plans s50's C-? Thanks JD Quote Link to comment Share on other sites More sharing options...
Jon Matcho Posted February 16, 2006 Share Posted February 16, 2006 I definitely don't think B will do because you've drilled all the metal away that you need for threads, and flox alone (a screw-thread thick on metal) is not the best substance to give a 28-32 TPI screw something to bite into, IMO. I vote for A, but injecting wet flox (or a metal-like epoxy instead???) to the surrounding area to fix what I think would result from drilling/tapping a hole that's now as wide as the plug you're drilling into. Is the attached picture an accurate representation of your issue (after you size up one diameter)? Or do the plans have you drill a hole completely through the plug? Option C is to glass it shut at some point, and before it departs the airframe into the prop. This is just my opinion -- please get more. Quote Jon Matcho Builder & Canard Zone Admin Now: Rebuilding Quickie Tri-Q200 N479E Next: Resume building a Cozy Mark IV Link to comment Share on other sites More sharing options...
John DiStefano Posted February 16, 2006 Author Share Posted February 16, 2006 Nice picture. Someone has a CAD program!! and too much free time. Quote Link to comment Share on other sites More sharing options...
Steve Innova Posted February 17, 2006 Share Posted February 17, 2006 It'll take you longer to fix it than to make a new one. Quote Link to comment Share on other sites More sharing options...
Jon Matcho Posted February 17, 2006 Share Posted February 17, 2006 Someone has a CAD program!! and too much free time.That "complex" shape took all of 2 minutes to make... good practice. I guess that's the issue you're looking at then. I saw the replies on the COZY list as well... I like Wayne's modification for this: http://www.maddyhome.com/canardpages/pages/waynehicks/chapter_09_5.htm Quote Jon Matcho Builder & Canard Zone Admin Now: Rebuilding Quickie Tri-Q200 N479E Next: Resume building a Cozy Mark IV Link to comment Share on other sites More sharing options...
John DiStefano Posted February 17, 2006 Author Share Posted February 17, 2006 Steve, what do you mean? I screwed up the slugs, not the cover. everyone, thanks for your input. JD Quote Link to comment Share on other sites More sharing options...
CFernandez Posted February 17, 2006 Share Posted February 17, 2006 OK, here's what I did. I drilled the #21 holes into the aluminum slugs.. 15 out of 16 came out real nice. One needs repair, only about 1/2 the diameter of the drilled hole is in the slug. But here is ther real issue. I read the directions wrong, followed them too literally w/out paying attention, I proceded to opening the slugs AND the gear cover with a # 11 drill bit. So, now, of course the tap does absolutely nothing and the S50 screws just drop in. Not good. So, how to fix. JD Jon, If I were to do it I would use milled glass fiber. I believe flox won't flow enough to fill the hole uniformly. With milled glass and epoxy you can put a lot of fiber into the epoxy and it will still flow. After it cures tap it. Quote Carlos Fernandez AeroCanard FG Plans #206 Chp. 13 aerocanard.kal-soft.com Sales & Support GRT Avionics Link to comment Share on other sites More sharing options...
Jon Matcho Posted February 17, 2006 Share Posted February 17, 2006 As suggested on the COZY mailing list, consider this product: http://jbweld.net/products/jbweld.php Quote Jon Matcho Builder & Canard Zone Admin Now: Rebuilding Quickie Tri-Q200 N479E Next: Resume building a Cozy Mark IV Link to comment Share on other sites More sharing options...
CFernandez Posted February 17, 2006 Share Posted February 17, 2006 I like the option to flox but would use milled fiberglass. You can put a lot of milled fiber in the epoxy and it will still flow easily it to the hole. You may want to use a toothpick to get any air out of the hole for a good fill. My 2 cents... Quote Carlos Fernandez AeroCanard FG Plans #206 Chp. 13 aerocanard.kal-soft.com Sales & Support GRT Avionics Link to comment Share on other sites More sharing options...
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