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From: "Scott Krueger" <sky2high@hotmail.com>
To: lancair.list@olsusa.com
Subject: LNC2 Stainless Steel Firewall - Holes and Such
Date: Sun, 18 Feb 2001 13:05:36 -0600
Message-ID: <F102AX3cf3ednHM3SOl00023419@hotmail.com>
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Rob,

I found that all the smaller holes in the stainless firewall could be made 
with the stainless backed by wood, lightly center punched and a pilot hole 
drilled with a 1/8 inch bullet point drill (won't wander, cheap, can be 
replaced easily when dulled) followed by a Greenlee step drill in your 
cordless hand drill.  There are two which are valuable - the 1/2 inch max 
and the 1 1/8 in max.  These are more expensive but will drill any material 
up to 1/8 inch thickness with a perfectly round hole and no chattering.  You 
can finish the hole by using the next step to remove (chamfer) any burrs and 
then do the same by back drilling or using an inexpensive de-burring tool.

For larger holes, use a compass to mark, stop by your local Radio Shack and 
pick up a couple of inexpensive hand nibbler tools (you will be able to wear 
them out), "nibble" out the larger hole and then (horrors) use a fine 1/2 
round file to smooth out to the final dimension.

BTW, you can file-smooth the outer edge and then, to really finish it 
nicely, get a $12 double-roller hand "beveling" tool from Aircraft Spruce to 
put a 1/4 inch wide slight bend "bevel" around the outside.  The bevel will 
also reduce the tendency to "oil can" in open areas.  This tool is used to 
strengthen lightening holes in aluminum ribs.

Scott Krueger
LNC2 N92EX

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Please send your photos and drawings to marvkaye@olsusa.com.
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