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Posted for Rob Wolf, re the subject.

Rob, in most places where I had to bolt something thru a hollow, or foam
cored, part of the airframe, I used fiberglass arrow stock - usually about
1/4 inch OD and just the right ID for a 3/16th dia bolt. The process was to
drill thru with a 1/4 in. bit (or clearance for the arrow stock you are
using), then carefully re-drill only one side with about a 3/8 th in. bit
going thru the core material but not thru the back side. I then cut a length
of arrow stock about 1/2 inch longer than needed so it would protrude a bit
on each side of the bulkhead (or whatever) and potted it into the hole with
flox. After the flox set up, both sides of the panel, and the ends of the
arrow stock, were sanded flush. If you need to match up to a hole pattern in
a part that gets mounted thru the holes, you can mount the part with waxed
bolts, lightly tightened, while the flox is still tender. This way, you only
need to sand one side down as the mounted part should pull up flush and give
you perfectly matched, and very sturdy mounting holes.

Dan Schaefer

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