Locate the Hole

During the course of an airplane building project, you might come across a task where you need to precisely match-drill a hole—a simple operation when the part with the existing hole is on top of the undrilled piece. But when the order is reversed, it gets tricky. You could do it with some masking tape folded over itself, but that’s not very precise. A strap hole duplicator is a tool that’s really handy and inexpensive, and it makes the task a breeze.

One tang has a pin that fits in the existing hole, and the other tang is fitted with a drill bushing. Place the pin in the hole you want to match, slide the undrilled piece into position over it, and drill through the bushing.

Here I’m fitting the rudder cap fairing and matching the existing holes and nut plates.
Matching holes drilled in the rudder cap.
Each duplicator is stamped with the drill size that fits the drill bushing precisely. In this photo, I’m drilling the fiberglass wingtip to match existing holes and nut plates in the wing.

A set of 6-inch duplicators costs about $40 at Yardstore.com.

Omar Filipović
Omar Filipović
A pilot since 1995, Omar is a GlaStar builder in Portland, Oregon and the president and janitor of the Glasair Aircraft Owners Association.

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Brian L
Brian L
10 days ago

This was not the tool I was looking for, but is absolutely the tool I needed.

Great recommendation!

John
John
10 days ago

Just used mine recently, but I forgot that you need to have all the holes on a piece located before drilling, otherwise the angle created by using one, throws off the location, then its a mess. You need a bunch