Drilling Jigs Info Please.

[Greg Mitchell]

G'Day Gents,

Am looking to produce drilling jigs for multiple mast and keel sections. Would appreciate advice on the best way to go about this. :confused: :o

Cheers,

Mitch.

[RossB]

Greg
talk to Jack Allen at the nationals. He made a great jig years ago
Ross B

[Greg Mitchell]

Cheers Ross,

Will do.

Mitch.

[Duchman]

I will try to attach a picture of what a simple drilling fixture for the mask or keel might look like. Fixture is made from a thick piece of angle iron. Angle iron would have to be machined in the inside. so you would have a square corner. the ends of the angle iron would also have to be machined square. I have placed black dots on the angle iron, to show where the holes go in the fixture. The distance from the holes to the ends of the fixture would have to be equal distant, from both ends. To use the fixture, clamp a stop to the part to be drilled as shown, and bump fixture against stop. (very inportant step, if you clamp the fixture to the part first, and then clamp the stop to the part, unclamp the fixture and rebump it against the stop again) ( stop is not needed if you decide to drill holes all the way thru both sides of tube) Drill holes thru one wall of tube, ( I would use a number three center drill, withdrawing several times to remove chips from flutes in center drill, try it yourself on a scrap piece first, makes a very acurate sized hole, with a minimum bur), remove fixture, and place it on the other side of part, and bump the other end of fixture against the stop , reclamp and drill holes in second side of part. I hope the picture shows what I don't know how to put into words. To bad that you don't live in the united states, I could make you the fixture, I do have the equipment, see picture. Also see gyro that I am building. tried to add pictures, but didn't work, give me your e mail address, and I will send them to you personally.

[Brian Jackson]

Duchman,
The picture obviously didn't show up. You have to click the "Manage Attachments" button that, unfortunately, doesn't show up unless you click "Reply" or "Go Advanced". I'm not aware of any way to attach photos in the typing area that appears at the bottom of any page you're reading. You must reply by clicking one of the buttons I mentioned above. Kinda sucks if you're unfamiliar with this board, but that's how it works.

I'd be interested to see the Jigs you're describing. Please re-post at your earliest convenience. If you have any trouble, email the photos to me (great-debate@peoplepc.com) and I'll post them here for you.

Respectfully,
Brian Jackson

P.S., please include your "real name" in your Bio. It's one of the requirements of this forum. Thanks!

[fun-flyer]

Greg,
Here is a jig I made (and will market if people are interested in it) from a piece of aluminum flat stock. A friend used it to drill his AC mast and the factory part lined right up.

I use 3/16" drill guide bushings to keep from the jig holes from being cut larger during use.

I have a 1 inch center line distance to 4 inches and there are two places where you can get a 3/8 inch space. You can do some combining and get several different hole distances. 1" 2" 2 1/2" 1 3/8" 1 7/8" etc. The holes are spaced across to give you proper hole edge distance off the side walls of a .125"W square tube. Hence no more having a drill cut into the side walls of the tube.

On the sides the jig has lines that are scribed at each holes exact center line. These are used to line up the jig for drilling.

What I do is measure to where I need to drill. Use a precision square to mark a fine pencil line on both sides of the tube all the way across. Then clamp the jig into place and drill the 3/16" holes on the first side. Remove the jig and clamp on the opposite side using the same fine pencil line for refference. Clamp the jig and drill the opposite side. Remove the jig and using a step drill you can open the hole to 1/4". Or you can drill through one side with a taper length 1/4" drill all the way through to the other side. Let the drill use the 3/16" hole on the opposite side to line it up. However the best method is a step drill you can buy at any hardware store or tool supply house.

Now something else I do is drill only one hole to size ie 1/4". Then bolt the assembly together using one side of the plates and make sure everything is lined up. If a hole is not exact when you drill through the tube into the plate the hole in the tube will make the plate hole correct. Then mount the other plate on and back drill it for finish size.

It has worked very well for me in keeping holes from having to be wollered out to get bolts in them.

Hope this helps your quest.

Greg Massey
President
PRA Chapter 62

[Duchman]

Brian Jackson,
I clicked on your link "email to me" but my mail was returned. Do you have a different E mail address, or send your e maill address to me. garytenpas@aol.com. I did what you said I should do to post the picture, but just couldn't get the job done.

Gary Ten Pas

[Greg Mitchell]

Greg and Gary,
Thanks fellas, great info and detail. I am not home yet from our National ASRA meet at Cooma. When I get home I will be sure to make contact with you both for further advice and clarification. I appreciate the help.
Cheers,
Mitch.

[Greg Mitchell]

Greg,
I just noticed you are in Houston Texas. I will be visiting with Larry Neal in or around Boyd Tx for a week or two before the PRA and Oshkosh this year and will attend both. Perhaps we can catch up at some stage whilst I am in the US.
Regards,
Mitch.

[fun-flyer]

You bet just let me know when your in Texas. For me it would need to be a weekend. The J O B just doesn't like me to take off during the week. Look forward to meeting you and seeing Larry again.
Grego

[fun-flyer]

To all those who may be interested in this jig. I have been asked to build some and what do they cost. The price for one with 8 bushings is $150.00. Email me and let me know if you'd like one.

[Greg Mitchell]

Hey fun-flyer,
Greg can you email me re these jigs. I'll try emailing you.
Mitch.

[Charles]

Hello Greg...
I case you needed a round tube drilling apparatus, here's an idea on making your own. If you have a small milling machine, weld two 3/4 iron angle under
one 1 1/2 on opposite side in a straight level.

For exact drilling, simply insert the jig in the table slot, center drill bit in center of jig, clamps down part and start drilling with pilot bit and finish with final size bit.

1 picture attached.

Charles Gagne
Quebec city P.Q.
Canada

[Greg Mitchell]

G'Day Charles,

Thanks Mate. I purchased a tube jig from Leaf or Spruce some time back. This is good info, pic filed.

Cheers,

Mitch.

[Greg Mitchell]

Thanks Duchman,
Got your email and pics. The RC gyro is very interesting and well made. How does she fly? Do you want me to post the pics on here for you Gary.
Cheers,
Mitch.