Tools

[t j]

Get a drill chuck and use it to turn and pull the chucking reamers by hand.

[jiott]

I believe this is a typo in the SS7 build manual. It should be 0.3125, a common size. The reamers for all the other size bolts are common sizes.

[Sabre]

Thanks Jim, I was wondering if this was a typo or not. Manual calls out a couple times for holes reamed to .3115 in different sections of the wing build; the root end of the rear spar and doubler plates installed at the root end of spars.

[jrevens]

I'm not so sure it is a typo. If you mic a few AN5 bolts I think you'll find that they are often less than .3125 in diameter. I just measured one at .3110. I bought a .3115 chucking reamer and used it when indicated. They're available - if you don't have a supplier of machine cutting tools who has one locally you can buy one online. FWIW, you'll probably be able to get a better, more correct fit for critical bolts like the spar attach points with .3115. If you've reamed oversize to .3125, you can perhaps get an assortment of bolts and find ones with a good interference fit, or use close-tolerance bolts.

[Sabre]

Thanks John, Reamers are not that expensive. I like your approach. I can always ream a little larger but not so much the other way. I appreciate the input!

[jiott]

You may very well be right John, but my experience in using the 0.3125 reamer that came in the tool kit supplied by Kitfox was that I had to run it thru the holes on the wing carry-thru tubes many times before I could get the AN5 spar bolts and pins to slide thru without excessive pounding. It would be interesting to hear the factory chime in on this one. In fact if I were Sabre I would give them a call.

[jrevens]

For sure Jim - whatever gives you a good fit. Some AN5 bolts will fit very nicely in a .3125 hole. It seems like they can easily vary a thousandth or so. The ones I got with the kit were on the smaller side. Having a larger diameter, your's are going to be stronger!