Aft Fuse Vertical Channels


Today I finally got motivated and made some good progres.  Here's the next #5 vertical channel blank.



Stopped by home depot on the way home and picked up a 1" hole saw.



I chucked up the saw in the drill press and there was a good 1/16th of an inch of wobble.  That translates into a hole that is 1 1/8th at least (if not bigger).  The center bit and saw are correct but where the hex drive was welded on it was crooked.  Unfortunately not much can be expected from a cheap (6$) tool.



After removing the hex drive the bit fits all the way into the chuck - nice and straight now.



It makes a nice clean 1" hole.  Its pretty cool that wood working tools work so well on AL.



Moving on - here's how I like to radius my corners.  I don't quite cut to the corner and then use a round file to radius the corner.  Then I use snips and files to clean up the edges.


Here's the #5 L&R vert channels.



The channel that will become the rear fuse vert channels.



See - Fuse Vertical Chanel...



Channel #4 cut and marked.



The flange gets trimmed off to clear other channels in the rear fuse when they make the frame.



The hole pattern on the vert channels is interesting to say the least.  I'm assuming there is a reason for the way its laid out that I just don't understand.



I'm sure the seemingly random spacing will become clear when I start assembly.  Probably something to do with the turtle deck formers.



The other end of the channel.



This end is not quite so complex.



The lower pilot holes drilled.



The upper pilot holes drilled.  I marked the 5/16th hole so I remember to drill the correct one up.



Marking the spot for the 3/4" hole.



Instead of spending the time to measure out the holes again I just clamped the channels together and match drilled.  This also has the convience of mirroring the hole pattern for the left and right parts.



The holes match drilled.



I was sure to use plenty of clamps so the channels don't move when I'm drilling.



Here's the match drilled part.  Much quicker than measuring out all 29ish holes.



Completed #4 vertical channels.



Conviently all of the channels have the same hole pattern at each end.  I can line up the end of the channel and match drill the opposide larger vertical channel.



#3 vertical channels.  Measuring out the holes took some time at the end but getting it right (or wrong) once replicates throught all of the parts made from the original.



All of the vertical channels that are made from vertical channel stock.  The last pair gets made from zee channel.



I used my unibit to drill the 5/16" hole.  It makes quick, clean cuts in the sheet and I don't have to worry about the bit grabbing like a regular bit can in sheet.



All of the 5/16" and 1" holes drilled in the vertical channels.



Cutting the zee channel is bit more of a challenge than the c-channel is.  I'll get it figured out though.



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