yup no square corners those are stress points the vibration you mention would start cracks there.
Those look like a standard reverse spotfacers that you can buy off the shelf. Just been modified to do the required job you have there.
Exactly what I thought. Just modified by grinding the radius on the outside of the cutting edge and the extra relief.
Personally, I wouldn't touch that with a ten foot pole. I would leave it to the licensed certified aircraft people that do that stuff,
Agreed. Me neither, but only because I am not licensed. Legal/insurance issues, not because it's a particularly complex job.
my buddy is an A&P IA (Airframe and Power-plant licensed aircraft mechanic, with federally recognized Inspection Authority), His assistant/employee is an A&P too. We have a long relationship as he has also maintained all of my aircraft on the side, but I'm the one with a bit of a machinist's background.
It sounds like he's the man for the job, just a little apprehensive that it's something newish. Like he just wanted a trusted second opinion from someone that uses rotating cutting tools often. I think your advice to him is sound. You may want to ensure that whatever lubricant is used is compatible with all the materials that will be exposed to it. (ie. no embrittlement issues) and that it can be removed properly, again with an appropriate solvent. There must be some recommended fluids.
although I can't guarantee you'd be 100% comfortable or at ease riding along
once it's returned to service.
From the sounds of it I'd have full confidence in the crew you have.
I do believe that no one cares about my truck brakes more than I do myself. I do use proper replacement parts, and do follow the manuals. But it's not rocket science.
However, for aero, I just don't have the time to read all the manuals and requirements.
Anyway thanks for all the pictures and great explanations and especially the pictures of the rental tools.
It's great to see the range of things different people do!
-brino