How to drill holes for control horns?

[rtn9105]

How to you guys drill the holes in your ailerons, elevators, and rudder for the bolt type control horns? The manual says to make sure the hole is drilled 90 deg to the center line of the control surface but how do you make sure the correct angle is drilled for each hole and that each hole matches the others?

[Znar]

Well sir, I finally had to use a drill Press...there may be a better way...

[rtn9105]

Thanks Znar
I thought of that also and so far it's the only way I've come up with to make sure all of them are drilled correctly. Unfortunately that will mean I'll have to go buy a drill press, I was hoping someone had come up with a different way, oh well.

[T.C.]

i used a buddys drill press and drilled a 1by 1 inch block with the same bold pattern in it then you can use a small drill on all of your controll surface

[dcoy]

I use a 3/4 inch steel block by 2 inches, I pre-drill the diff type of horn patterns using the drill press, with steel it wont eat away as you use it. To make the block, drill the first hole, as you finish each hole, put a horn screw in that hole, this will keep it from rotating once you get to the third and fourth holes, this will keep it square all the time. Then use the dremel and have at it, perfect alignment every time. I also use the Wallmart clamps, on each corner so it wont slide around on the control surface, and the dremel being so light is easy to finesse, Hope that helps!!

[Jaybird]

I use a drill press. Block up the surface so the holes go in perpindicular to the centerline. You can buy a cheap benchtop press at harbor freight for about 40 bucks that works really good.

[Mark Davis]

Sooner or later you're going to need a drill press... Especially for drilling props properly... I picked up a bench-top Ryobi from Home Depot on sale for under $100...

Besides, power tools are cool...