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Match Drilling a New Tailwheel to an Existing Hole
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Lessons-learned submissions follow a standardized format designed to identify the issue, draw out the relevant factors and present useful guidance to others facing a similar situation. The submitter answers the following 5 questions:
1) What went wrong (or right), and why?
2) What were the shortcomings, and why did they exist?
3) What actions were taken to fix the problem?
4) What preventive actions should be taken into account for future efforts?
5) What overall recommendations should be made for future projects?
The length of the write-up and amount of detail presented are left up to each individual. Some lessons learned can be perfectly conveyed in a few simple sentences, while others will require much more. The goal is to be as clear and succinct as possible, not to generate literary masterpieces!
All posts submitted to this forum are held in a review queue for approval by a moderator. Information in the posts will be reviewed, vetted, and modified as needed before going public. Additionally, any replies that are submitted would also be reviewed to ensure they add value and remain on topic. This will avoid normal threat drift of general discussions.
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Match Drilling a New Tailwheel to an Existing Hole
by sonex1374 » Sun May 31, 2020 10:38 am
Installing a new tailwheel assembly onto an existing tailwheel rod requires the builder to match-drill the new tailwheel pivot assembly to the existing hole in the titanium rod. This can be a challenge because the new pivot covers the existing hole from view once slid onto the rod. Fitting this accurately requires a jig to ensure a tight fit.
A simple jig can be fabricated similar to the photos below (original source: Steve Sonex #892, viewtopic.php?f=45&p=42813#p42804). The jig ensures the 1/4" drill bit will remain perfectly aligned with the existing hole while you drill the new pivot.
For even greater accuracy drilling the new pivot holes, insert a reducing bushing (1/4" OD x 1/8" ID) into the jig hole and use a 1/8" bit to pilot drill the new holes. Once the pilot holes are located using the bushing, the bushing can be removed from the jog and the holes up-sized to 1/4".
Jeff
Keywords: tailwheel upgrade, match drilling
A simple jig can be fabricated similar to the photos below (original source: Steve Sonex #892, viewtopic.php?f=45&p=42813#p42804). The jig ensures the 1/4" drill bit will remain perfectly aligned with the existing hole while you drill the new pivot.
For even greater accuracy drilling the new pivot holes, insert a reducing bushing (1/4" OD x 1/8" ID) into the jig hole and use a 1/8" bit to pilot drill the new holes. Once the pilot holes are located using the bushing, the bushing can be removed from the jog and the holes up-sized to 1/4".
Jeff
Keywords: tailwheel upgrade, match drilling
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