I claim: 1. $29.95. Note: six ribs were "perfect" the . --> Zenith-List message posted by: "Don Gordon" <djgordon@bigpond.net.au> Hi Carlos I went through the same faze I made the 2 dies from a dence plastic sheet ( polyethelene ) spun them on the lath with a centering plug put the piece into the die and just hit it with a large hammer work out perfect Don ----- Original Message ----- From: "Carlos Sa" <carlosfsa@yahoo.com> Subject: Zenith-List . These are too heavy to post, so collection is required. In three evenings on the lathe, he turned three different sized flanging dies and then flanged every lightening hole on the fourth. $10 Off Your Mobile App Purchase . One of the best examples of this are the flanging dies Ron had custom made at a machine shop. Yup. The various vertical and horizontal fin ribs are now formed, still to complete are the flanged lightening holes, but these are on hold as I have ordered a set of combination punch, and flanging dies, and they are enroute via dogsled or similar based on how long they are taking! . SONERAI Pictures. Ball bearing style rollers. Find Flanging Dies and get Free Shipping on Orders Over $99 at Summit Racing! . They are tough-enough to use with a hammer or a press. Gentile Judaism. The stiffer part is often overlooked in discussions of lightening holes. Flanging metal is the act of swiping sheet metal in a direction contrary to its previous position. Dimple dies, punch & flare, and flare only tools add that 'trick' look to any metal fabrication project. See the whole series, "Making a Sheet Metal Rib from scratch" under the Scratch Building topic area. see picture for sizes. Designed to strengthen panels with lightening holes, we offer several different styles to choose from. A real time saver for flanging lightening . Just stuck the flanging die images here . The taper in the bottom side of the hole is relative to the die clearance. I'm talking in particular about lightening holes and inspection holes. V-block forming The process is widely used in press-working operations to strengthen the edge of the holes, to . If I had to guess, I would say I have at least a man-day or two in each . Dimple Dies will work in material as thick as 1/8 inch chrome-moly steel and are meant to be used in an ironworker or press. 1) Dimpling with a hydraulic press (EASY BUT NON-MOBILE) This is an easy way to use your dimple die. Drill Size Maximum RPM 80-30 500 29-U 300 3/8 150Working Stainless Steel Figure 4-167. A hole-flanging operation on a flat circular sheet with a hole in the center is simulated by an incremental elasto-plastic finite-element method, which incorporates strain-hardening and anisotropy . Forming blocks are routinely used to flange the edges of the ribs, especially where curves require inside or outside flanging. There is a heap of stuff about doing this sort of work on the internet and there will be videos on you tube too. Bumping Used to form annealed 3003-O or 5052-O aluminum with a forming block and mallet Flanging Lightening Holes Decrease weight by cutting holes in material Adjustable fly cutter or hole saw Increase rigidity by flanging the . I will do mine by using the two formblocks and a die block also made from the MDF wood. For forming flanges around lightening holes. The spar fittings were prepared and clamped. In the stretching method, place the flange to be stretched in the groove of the V-block. Used on aluminum skin .025 thick or less Accomplished by using dimpling dies and hammer or press Two types Modified . Lightening holes are cut in rib sections, fuselage frames, and other structural parts to decrease weight . I watched the video on the EAA website about making the wing ribs from scratch and noticed he had a flanging die that looked to be made out of some heavy duty plastic. "Going all the way around with a [hand] flanging tool can take 20 minutes a rib," Clagg said. Belling or Flanging Dies Belling or Flanging Dies Homebuilders, both of airplanes and race cars, often want to put holes in things, both to lighten, and when properly used, to stiffen aluminum structures. . Flare Tools & Punches or Punch Sets for Aircraft Fabrication The uncoordinated flanging height resulted . Light Racing Flared Hole Dies 15810. FLANGING-360 TOOL from Aircraft Spruce RIVET SHANK REMOVAL PLIERS from Aircraft Spruce The hydroformed stiffeners will take a hefty press and some thick sheet rubber. Numerical simulation is an economical and convenient method to predict the deformation behavior during the flanging process. The investigation showed that the low geometry accuracy around the elongated hole flanging attributed from an uncoordinated deformation occurred, including unequal flanging heights and different rebound amounts between the straight edges and the circular edges. When I set the flanging die up on the bench, I noticed that although my lightening holes are cut to a perfect 65mm diameter as per the plans, the outside diameter of the flanging tool above the shoulder (the one on the left) is also exactly 65mm, making it too tight a fit in the hole, and impossible to . Clearance: Definition. VW Powered Homebuilt Airplanes. 11/11/02 Added articles on Collaborative Homebuilding (airplanes) and Flanging Dies for Lightening Holes. Will not mar material. The few grams that are saved from each rib are negligible but the simple flange around the hole makes an enormous difference . deathrowdave. These are the 4" or 4 1/2" flanging dies for the spar lightening holes. The cross section of a punched hole is shown below. "Properly" in this context means putting a flange around the hole. Available in 3 inch and 4 inch diameter, Sonex flanging dies are made from durable fiberglass reinforced injection molded plastic. TTFN FAQ731-376: Eng-Tips.com Forum Policies $39.95. You can also buy commercially made flanging dies. . when forming a lightening hole, make one hole with a fly cutter, smoothing the edges so there will be no cracks or scratches that could cause a tear when the metal is stretched.use a flanging die made of steel or hardwood, such as is seen in the figure and centre the hole in the metal over the male die; then force the dies together in an arbor Hole flanging is a process often used in industry and often described in the literature. $5 Off Your $100 Mobile App Purchase . Made from 2024 aluminum and hard black anodized. If it DOES have a through-hole, you can use any of the listed methods. . 18 gauge capacity. Fit the die pieces and work piece in your press. In three evenings on the lathe, he turned three different sized flanging dies and then flanged every lightening hole on the fourth. 374FC. It took a while to make the dies, but now it's going real quick. . Working on skinning the left wing! . We're planning to use the Bob-stick. Excellent for flanging lightening holes or overlapping sheets. Technical PISSED OFF Cutting Gauge Holes. The die method makes the flanges nice and even. Used to form a bend or flange in the center of a sheet of metal without distortion, such as lightening holes or beads in the center or a rib or bulkhead. He told me they worked very well. You drill a hole in the work piece. With the milling machine he quickly cut every lightening hole in the airplane. Flanging Dies. BEADING DIE #8 (1/2") 12-342-20-8. Due to popular demand, Sonex Flanging Dies are back in-stock! The air cylinder fixing flange is fixed on the die body. used for making unusual shapes and bends such as: straight. The flanges stiffen the web considerably even though all of those holes only remove 3.7 ounces from each spar. June 17, 2007 11:08 AM Subject: Zenith-List . Comes with spare set of rollers. Using draw set instead of the female die, and hammer the rivet until the dimple is formed. HOLE FLANGING TOOL - For forming flanges around lightening holes. narfi wrote: Wed Sep 23, 2020 9:05 pm Need to make some flanging dies similar to this, flangedies2.jpg. The authors present both traditional winding methods [1] [2] [3] as well as other solutions, eg. Page 2 of 2 < Prev 1 2. Here's how we're flanging our lightening holes. For flanging soft metal, dies can be of . Describe lightening holes. You design specific ribs, trusses, etc., that take their respective loads without being completely solid. This is how I flange the lightening holes in the nose rib. The blue flanging dies I bought from Sonex in the USA but you could make them out of timber or aluminium and spinning them up on a lathe. Set of 3 steel flanging dies made for Zenith 701, but would suit any homebuild aircraft. Lightening In the Hangar. In addition, cutting lines must also be marked for material to be removed so the cor-ners can be fabricated. posted by SCRAMJETTER at 10:55 PM . Divorce Sucks. lightening holes that is.. the next step is to tackle the front end. Ribs and spars are usually already designed for minimal weight. Contact Details 07772722015 $18.95. pressed around the holes to strengthen the area from which the material was removed . Frequently Purchased With Customers Also Viewed SUPER COBALT DRILL #40 $1.70 HAND SEAMER W/ROUNDED CORNERS $73.75 10 HOLE ADJUSTABLE RIVET SPACER $29.50 20 HOLE ADJUSTABLE RIVET SPACER $48.85 The Sonex flanges are exactly the kind of die I'm looking for. I bought the NOAH FLANGING 360 TOOL from A/C Spruce, I saw a video of it in use on YouTube, and figured the money versus time savings making forming dies would be worth it. Frequently Purchased With Customers Also Viewed CIRCULAR HOLE CUTTER #04 $17.60 ECON FLUTING PLIERS NO COATING $27.55 AVERY DOUBLE EDGE DEBURR TOOL $23.50 FLUTING PLIERS $23.50 The lightening holes were circTilar and had either flanged edges or "beaded edges, the specimens with flanged edges constituting by far . As seen in the image below, I began by breaking the edges of the lightening holes. Getting ready (Zenith workshop, 16' table, CNC, and flanging dies) Building wing ribs Metal Brake lessons Corrosion protection Metal Brake redesign Angle Iron Brake Plans Bending the Main Landing Gear. Discussion in 'The Hokey Ass Message Board' started by Clik, Feb 23, 2020. This can be attributed to two reasons: (1) the single-side clearance between punch and die was c = 3.4 mm, which was larger than the initial sheet thickness; (2) the sheet mouth area exhibited a significant thinning phenomenon. holes. but it will get lightened as well. Used to form a bend or flange in the center of a sheet of metal without distortion, such as lightening holes or beads in the cnter or a rib or bulkhead: Term. Use the croquet ball for nearly any size hole smaller than the ball, and voila! cut every lightening hole in the air-plane. "Going all the way around with a [hand] flanging tool can take 20 minutes a rib," Clagg said. I borrowed the flanging tool in the picture below from my buddy Garet . The various vertical and horizontal fin ribs are now formed, still to complete are the flanged lightening holes, but these are on hold as I have ordered a set of combination punch, and flanging dies, and they are enroute via dogsled or similar based on how long they are taking! and Yang et al. Also you will need some thick steel plates to use to sandwich the part, form and rubber. . Flare tools, aviation punches, metal punch sets, dies, instrument gauge hole punches & metal fabrication tooling supplies available direct from Mittler Brothers. I used an air powered die grinder with a 3M wheel. This makes short work of both the edges on the hole and the 3M wheel itself. A flanged hole! Lightening Hole: Definition. Using a round, soft-faced mallet, strike the flange directly over the V portion with light, even blows while gradually forcing it downward into the V. Figure 1. Me so dumb. You are here:Home > SHOP MORE > Paint & Body Equipment > Hole Drilling, Metal Cutting, Punching & Flanging Find by Pricing Below 30 (2) 30 to 106.99 (2) 107 to 162.99 (2) 163 and Above (4) Find by Brand Astro Pneumatic (2) Blair (1) Dent Fix (5) Killer Tools (1) Steck Manufacturing (1) Typically you will use a fine grade. Easy to use. Flanges from 1" and up. from NKy. A 14' jig was made that would hold the spar center section and one outer spar at the correct angle. There are several specialty tools available to. Easy to use. Profile Page. Made from 2024 aluminum and hard black anodized. to be moved when I have time. Labels: Wing. This is to stiffen the rib web and reinforce the hole edges. Nylon rollers and ball bearings assure long life. Further weight reduction would most likely incur a loss in strength. This video demonstrates the techniques for using a fly cutter to cut a lightening holes in a sheet metal wing rib blank, for those who are scratch building. A cutting and flanging tool comprising: a male punch member having a cutting edge at the leading end thereof and a deformation surface located spaced rearwardly of the cutting edge; a double ended female die member having first and second ends, the first end of said female die member cooperating with the cutting edge of the male punch member to cut a hole in a workpiece by removing . Nylon rollers and ball bearings assure long . hole through wall in "A", "B". Ball bearing style rollers. Hole-flanging is a conventional forming process in which a sheet blank, with a concentric pre-cut hole and the outer periphery rigidly fixed by a blank holder, is forced with a punch around a die to produce a smooth cylindrical or conical hole-flange. skin, core & inner skin damaged in "C". Comes with spare set of rollers. In the front of the picture below are the two halves of the 115mm diameter flange die - female side on the left, male on the right. I like this method better. The key to making ANY flanging die set work is to ensure that the small end of the male die JUST clears the deburred hole that you make in your parts. Flanging Dies: Definition. It's a great tool, but the wheels wear out pretty quickly. Wen et al. DELUXE TUBE CUTTER. Sheet Metal Flared Hole Dimple Dies, 2 Inch Visit the Speedway Motors Store 54 ratings $5798 Size: 2 Inch 1-1/4 Inch 1/2 Inch 1-3/4 Inch 2 Inch 3/4 Inch About this item Sheet metal flared hole dimple dies Dies come with a black oxide coating Available in a variety of sizes All sizes feature a 1/4" radius It's under the Homebuilder section and the sheet metal tab, "Sheet metal rib from scratch, part 5 - Flanging". An alternative to the manual method is to use a 3M Roloc pad on a die grinder. Usually lightening occurs as an integral part of the design. Nonmarring. HOLE FLANGING TOOL. Overview A real time saver for flanging lightening holes. The spar fittings were prepared and clamped. 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