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I just used snips. I hate the fly cutter.
Also, I had interference with the trim attach tab on the yoke. Would rub the bottom of the pan. I shimmed the seat at the edge of the spar box to get enough clearance.

142YX wrote:

MichaelFarley56 wrote:Just mark new lines, grab the fly cutter, and use a wood base under the seat for support when you cut new corners. It's really not that bad.

Ill have to try this.. it was my thought that using a fly cutter after the hole had been cut would be problematic as it hits the edge of the pan with each pass.

I had to make a part this weekend this way, and also wondered about it. turns out it's not a problem at all if you use light pressure on the fly cutter. Mine was done on the drill press though, you'll probably have to be a little more careful doing it with a hand drill.

A word of warning ,a fly cutter in a hand drill will destroy your aluminum or at least the look of it in about 2 seconds.It is possible to use a fly cutter manually ie: turning it by hand,it would take a while but it would work.No animals were harmed when I tested this method years ago in wood :oops:

Hi Mike53,
Respectfully, not true on your statement above. I used a fly cutter in my hand drill to cut the seat and it worked just fine. The trick is to have a piece of plywood behind the aluminum. Don't go high speed, just take your time. I did this for the seat and the fuse sides where the pushrods come out for the ruddervators, no problem. All told, I did it using he hand drill a total of ten times with no issue at all.
Lorin
N81YX

Good to know. I've only tried it on wood and I found it impossible.I would still probably turn it by hand but then I'm scared of sharp knives also :?

Mike53 wrote:I would still probably turn it by hand but then I'm scared of sharp knives also :?

:lol:

You're probably a lot smarter than I am...I have a lot of small cuts and scrapes all over my hands attesting to inadequate respect for sharp things. :?

Not smarter just older. I've probably had 25 more years than you of cuts and scraps to temper my enthusiasm. It's been said that old age ain't for sissies. ( Not that 58 is old :| )Maybe so,but I still won't run around the house with a pair of scissors like I used to. :shock:

Over the past two weeks, Waiex # 142 has stood up on her own feet for the first time. I also have outgrown my crowded garage and moved the project over to a hangar at KMHV! Engine should be here in 2-3 months.. and i hope to have a significant amount of work done on the wings by then. Motivation is really high right now!

Most excellent! :)

Hey that looks great! Keep up the great work! It looks like you're about ready to fit the wings so you can finish the spar tube assembly...or have you already?

Keep the pictures coming!!