Drilled my first part today

[Brian Jackson]

Howdy all.

Well I'm a "happy camper" tonight. I spent a great deal of time practicing on scrap material and asking a lot of questions here (for which I'm grateful to those who took the time to respond). I promised myself I wouldn't drill any actual gyro parts until I could produce 20 perfect holes in a row. Turns out that center-punching accuracy was the single most critical phase in the drilling operation. But I came up with a multi-step process that's working incredibly well for me. After deburring I threw a micrometer on the holes to check center locations and all were within a couple 10/thou of hairline center. Even more startling was that, the multi-step punching I experimented with actually enables me to drill more accurately by NOT clamping the parts to the drill press bed. Believe it or not. The precise divot shape I make auto-aligns the bit travel.

Anyway, I'm now the proud owner of a nice 17.5" Rudder Pedal Brace. I scribe the center crosshairs through blue layout fluid using a calliper micrometer, and am getting pretty good at positioning the center punch purely by feel. Never realized before how important tactile feedback was.

It's a small step, but a big leap forward for me. Because of the precision needed, I've been waiting and practice-drilling for weeks in anticipation of this. I don't have the funds to replace parts... so I'm extremely happy right now to have drilled my first part and it turned out perfect. Live and learn!

Thank you,
Brian Jackson

[B8MFlorida]

Brain-
Good for you-
It's always nice for a part to come out looking like a jewel and to plans.
Before you know it,you'll be whipping out pieces Like a one-man aircraft Company.
Anyhow just wanted to encourage you......and tell ya........I'm very happy for you. What part is next..................?
John Rocca
Naples Florida

[Brian Jackson]

Brain-
Good for you-
It's always nice for a part to come out looking like a jewel and to plans.
Before you know it,you'll be whipping out pieces Like a one-man aircraft Company.
Anyhow just wanted to encourage you......and tell ya........I'm very happy for you. What part is next..................?
John Rocca
Naples Florida
Thanks, John.
Next part? Hmmm... I'm thinkin' maybe the Subwoofer brackets :D
I'll probably continue with the rudder pedal assembly; tolerances aren't ultra critical. Won't be drilling the mast until I'm more confident and get a few more parts like these under my belt.

Thank you for the encouragement. I can't expect anyone to share my enthusiasm for something as seemingly simple as drilling a hole, but knowing it's being done right affords a sense of peace. After all, it's not like building a patio deck!

Take care,
Brian Jackson

[Tom Evans]

I've seen patio decks built so poorly I dared not set foot on them! Then also others so beautiful I couldn't stop looking at them. Workmanship is workmanship.

[scottessex]

Just wait till the elation when you spring for an "automatic center punch" the spring loaded type, just line up, push, "POP" and you're ready to drill.

Then you'll want a mill, and a lathe and an air compressor,and...............

[ultracruiser41]

If you're like alot of us "tinkerers'" you'll spend alot of time sitting there "admiring" that wonderful part you just made and smiling! :p

People that don't like to tinker just don't understand that building it can be just as fun as flying it!


BarryK

[Brian Jackson]

Amen, Barry. But rather than sit there and grin at it, success should be a motivator. At least it is for me. Otherwise what's the point?

Thanks,
Brian Jackson

[donshoebridge]

Brian,

Any pictures that you can post would be a great influence for the rest of us struggling builders. :)

[Heather Poe]

Brian,

If you are interested in a high degree of accuracy, especially for repetitious machining, consider using a CNC (computer numeric controlled) mill. I used one to machine Randy Coplen’s Sparrowhawk instrument panel. Good vendors are:

Sherline:
http://www.thesherlineshop.com/store/index.php?shop=1&cart=47578&cat=1&

Flashcut:
http://www.flashcutcnc.com/html/mach_2000_5400.html

Taig:
http://www.taigtools.com/

Desktop mill list:
http://www.desktopcnc.com/mfglist.htm

best wishes,
Heather

[Brian Jackson]

Brian,

If you are interested in a high degree of accuracy, especially for repetitious machining, consider using a CNC (computer numeric controlled) mill. I used one to machine Randy Coplen’s Sparrowhawk instrument panel.
Hi Heather.
Thank you for the links and recommendations. I'm familiar with CNC gear... even designed the protocol for some of the equipment. Cost is the only excuse I can offer for not utilizing it currently. Since being laid off this Chrismas, the term "shoestring budget" has new meaning. :D

After a month or so of intense practice, accuracy is near-CNC quality with only the modest tools afforded me. I started with the pedal assembly since they're mostly non-stressed, non-structural items. I figured if I screwed up a drilling operation there, they're mostly short pieces I could recreate with little cost, unlike a mast or keel. Thus far I'm extremely pleased with the level of accuracy I'm maintaining. It's good practice too.

Regarding CNC'd holes though... I did note some wall thickness variations in my 2X2 tube. Nothing Earth-shattering, perhaps .008" max. between adjacent walls. But enough to note. It's T6 direct from Wicks, so I'm wondering if there's ever been a case of inside wall scoring when CNC'd. Worst case scenario is adding max tolerances together. For example there's only .031" tolerance between a hole wall and the inside wall of a GyroBee mast. If each is off collectively by .015", the part is ruined from interior scoring. I know Dana at StarBee Gyros is CNCing many of their components. I suppose I'm just curious if wall thickness variations are factored. Typically extrusion manufacturers machine tubing dies as separate components to be unitized prior to a production run. So their machining tolerances result in those of the tubing itself.

Man, did I get way off track here or what? :D . The one area I'd like to CNC though is the geometry of the plate stock. I've incorporated some very subtle spline curves that would be extremely difficult to replicate by hand. Doesn't change the stock Bee design at all, but adds a hint of "eye candy" that gives it a more fluid feel. Purely cosmetic.

Heather, thank you again. Your profile indicates you're an engineer. It's always nice to talk "geek" with someone in the know :D

With gratitude,
Brian Jackson

[Jazzenjohn]

Using the calipers is OK if you make sure that the edge of the part is square and in good condition. Also pay attention to keeping the non scribing edge of the caliper straight and square. There is a device for center punching scribed lines that is very accurate and relatively inexpensive called the optical center punch where you use a reticle to line it up, replace it with a punch, then mark it for .001 accuracy. It's on Mcmasters page 2129 ~$70 (if you have trouble getting the center punch mark on the scribed lines)

[Brian Jackson]

Using the calipers is OK if you make sure that the edge of the part is square and in good condition. Also pay attention to keeping the non scribing edge of the caliper straight and square. There is a device for center punching scribed lines that is very accurate and relatively inexpensive called the optical center punch where you use a reticle to line it up, replace it with a punch, then mark it for .001 accuracy. It's on Mcmasters page 2129 ~$70 (if you have trouble getting the center punch mark on the scribed lines)
Hey Jazz!
Thanks. I'll look into that. Good points about not basing dimensions from unknown surfaces. Since all surfaces are relative to one that's fixed, I try to base all measurements from a datum. Even when scribing from the caliper mic the reference point is held critical. Even a seemingly shallow arc angle can throw a measurement off.

By the way, John, where is Canton? Are you building or flying currently? I'm in Niles and always interested in hooking up with folks whom share a passion for gyros. Meet for lunch sometime?

Regards,
Brian Jackson

[Jazzenjohn]

I'm a couple hours SE of Niles near I-275 and I-94. I would like to see your gyro when it's a little further along. Right now I'm in the early stages of "the bug". I just came back from some initial lessons with Terry Eiland in Florida to see if I'm mentally and physically able to fly them. I'm usually sleeping around lunchtime as I'm a Vampire (Midnight shift). I'm going to try to make it to Three Rivers and Mentone this year so I'm sure I'll see you somewhere soon.