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Date: Fri, 09 Apr 1999 10:45:12 -0400
To: lancair.list@olsusa.com
From: Marvin Kaye <marvkaye@olsusa.com>
Subject: Re: Bolt tolerances, fixes
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There have been several excellent responses about what to do with holes
that have been slightly misdrilled off-angle.  I imagine that most builders
have suffered this malady and have taken the flox filler approach as the
solution.  Naturally, the best solution is to not have to have a solution
in the first place.  While a mini portable drill press offers the greatest
promise for keeping holes perpendicular, there are many instances where
locating one of those things where the hole needs to be is going to be
quite impossible.  All is not lost, however, as there is a simpler solution
readily available at the local building supply store that will provide you
with just about perfectly perpendicular holes as long as there is a 3"
diameter circle of flat area surrounding the intended hole location.  

If you go to the local Builders' Square, Home Depot, or Lowe's store, you
should be able to find a "lockset drilling kit" in the tool department.
This kit consists of several items, one of which is the solution to this
problem... the kits typically include a 7/8" spade bit, a 2-1/8" hole saw
and a drill centering/alignment fixture to help with the drilling of the
holes that center the locking bolt in the edge of the door.  This fixture
is typically a plastic cylinder, about 3" in diameter and 1.5" thick, with
a 5/32" pilot hole drilled straight down its axis.  If you put this fixture
flat on whatever it is you're trying to drill and use the piloting part as
intended you'll get your holes running as close to perpendicular as is
possible without the use of a drill press.  The whole kit only costs aroud
10 bucks, but that fixture alone is worth the price of the whole kit
itself.  I've used one extensively on my project and have never had to fill
a hole due to misalignment... mislocation due to improper planning, well,
that's another story entirely....

    <Marv>

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