22 Nov 05 - Engine Hoist, Battery Box Stuff

Still working on the battery box - well, this is actually the second battery box, as I never really got happy with the one that I messed up earlier this month. It didn't line up quite right, and I thought I could do it better, so this is the second one.

Oh yeah - this is the other big thing that is going on - we now have (in the sense of "we're borrowing it") an engine hoist from Ken, who I don't think was expecting it to ever be used for an aircraft engine.
Back to the battery box - cutting the lightening holes with a hole saw. The plans call for a 2 inch hole, what I've got is a 1 3/4 inch hole saw. Not worth buying another hole saw for that, so the holes will be a little undersized.
Dimpled and with the holes cut in it. Just needs to be painted, now.
Ah hah! This is the rivet that should be drilled out for the bolt for the battery box. As you can tell, we missed the rivet. Discussion is below.

Okay - here's the rationale behind drilling that rivet in the wrong place . . . or what looks like the wrong place, to all you people out there in internetland. When I held the battery box up to the firewall, it became clear that drilling the battery box to the battery box braces on the sides (what's just been put on in this picture right here, even though that's not supposed to have happened yet) would make it not fit. The battery box was just a bit too wide, and would not be sitting level. The placement of this hole was guided by (a) trying to get it level, and (b) trying to get the hole for the screw onto that blue line. Why on the blue line? Because the stiffener that this is drilled through is a piece of L-shaped aluminum, if the hole was just pushed to the right or left, there would be edge distance issues. The blue line that is in this picture is drawn over the center of the stiffener on the other side. Again, in this picture you can see how one brace sits lower than the other - that's intentional - that allows us to get it level and have the screw go through the right place on the stiffener.

You can peek into the future to see the finished result. It came out well.

Of course, the other issue here is that now the screw head is going to run into the rivet head that is right next to it (this rivet is not flush on the other side, too), so that'll have to be ground down, probably using the dremel, a file, and possibly some bad words, too.

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