Horn timber progress - angled hole?

[Rich VanValkenburg]

Well, I'm going to make a similar repair to the horn as I did the forekeel, but the horn will be a glued joint. The only area of rot and severe checking is at the rudder shaft through-hull. I'm looking for a good idea on how to drill the hole at the proper angle. The only thing in mind at present is a starter block drilled on a drill press, and then clamp that to the horn as a guide. Anyone have a better idea?

http://www.imagestation.com/picture/sraid23/pde61474d61c7fa6957e18afb7188cfef/fd9e2cd1.jpg
http://www.imagestation.com/picture/sraid23/p461bd862d3d7094704e8177e35340a4e/fd9e2ccf.jpg

Rich

[Dave Fleming]

As long as the jig block is long enough to assure accuracy, I don't see why not.

[RGM]

Nice pictures, as usual Rich. I take it that you'll be drilling this in place after the new piece is glued into position? As Dave stated, your jig or fixture should be fairly substantial. Additionally, since much of the alignment depends on taking the pintle into account you might want to consider a jig (at least for lay-out) that can reach from the pintle to your deck/cockpit penetration and reach around your horn timber. This would help you confirm the top and bottom locations of the center for the hole that you will drill. You could then drill a pilot hole, using a jig, confirm you hit both centers, or adjust accordingly, re-drill, then chase it with the final size cutter or drill. You could drill 1/2 of the hole from each direction and meet in the middle. You could get fancy and build a plywood drilling jig that looks like an educated c-clamp that orients and secures to both sides of the horn timber at once. Those work well for longer, more fearsome holes. Good luck.

[Rich VanValkenburg]

Pilot hole....pilot hole.....cool! Didn't think of that. Yes, that would confirm the lineup. Pilot hole with a wire through to deck and pintle. That would be easier than drilling a 1 1/8" mistake. As far as drilling in place, I don't think I want to do that. Just not enough room below deck for me, drill, swear words, etc.

I don't know, but to me, the photos never come out the way that I see it. Thanks anyway.

I might scrap that new horn as it is. It's developing a check right down the middle despite lots of oil.

[Ed Harrow]

If it were I, this is what I'd do.

First I'd go to my buddy Ralph, the machinist, and, bringing that bit of horn along, I'd ask him to make me a plug to fit that hole, with a 1/4" hole dead center.

Then I'd fit the horn piece back in and make a jig to test the fit.

If it all looks good, take that bit of horn and, if your drill press has a rotatable table, you could set the table at the correct angle using that plug and a suitable bit. Now all that you have to do is to get the hole into the correct place so, using that bit of timber, make a jig on the table holding it in the position it is now in. Lift the quill, remove the bit of horn timber, replace with the new, close your eyes, give it a pat for good luck, drill the hole.

Go back to Sonya, try the fit with the jig you made as recommended by Rodger, I think, and voila, perfect (if small). Return to the drill press, which you've left undesturbed, and start stuffing bigger bits thru the hole.

Should work.