A wing skin, which was secured to a wing structure by a plurality of fasteners extending through the wing skin, is removed from the wing and aligned with a template. Template holes are drilled through the template corresponding to each of the fastener holes of the wing skin. The template is then aligned with a new wing skin, and pilot holes are drilled through the new wing skin corresponding to each of the template holes. The new wing skin is then aligned with the wing structure such that the pilot holes permit access to corresponding fastener holes of the wing structure. A mill bit is then positioned through each pilot hole and aligned with the center of the corresponding consumable bushing in the fastener hole of the wing sub-structure, and the skin pilot holes are milled to form fastener holes in the new wing skin aligned with existing sub-structure.

A wing skin, which was secured to a wing structure by a plurality of fasteners extending through the wing skin, is removed from the wing and aligned with a template. Template holes are drilled through the template corresponding to each of the fastener holes of the wing skin. The template is then aligned with a new wing skin, and pilot holes are drilled through the new wing skin corresponding to each of the template holes. The new wing skin is then aligned with the wing structure such that the pilot holes permit access to corresponding fastener holes of the wing structure. A mill bit is then positioned through each pilot hole and aligned with the center of the corresponding consumable bushing in the fastener hole of the wing sub-structure, and the skin pilot holes are milled to form fastener holes in the new wing skin aligned with existing sub-structure.

The invention relates to a portable drilling and/or boring machine, for workpieces (8), in particular workpieces that make up aeroplane structures, such as airframes, wings, cabin, the machine comprising: a jig bushing (3) for guiding a machining tool; an expansible clip (4) for blocking the jig bushing in an opening of a screen (5) positioned on and secured to the workpiece, said screen constituting a drilling jig; and a means for moving the expansible clip (4) in order to clamp and unclamp the jig bushing and secure the machine relative to the screen; the means for moving the expansible clip (4) relative to the jig bushing (3) includes an electric motor (1) the torque and position of which are controlled.

A jig for forming holes in a workpiece includes a body. The body includes a first jig-surface and a second jig-surface. The first jig-surface includes a jig-surface contour. The jig-surface contour is complementary to a workpiece-surface contour of a workpiece-surface of the workpiece. The second jig-surface is planar and opposite to the first jig-surface. The jig includes through holes that extend through the body between the first jig-surface and the second jig-surface for forming holes in the workpiece. Each one of the through holes includes a through-hole axis that is perpendicular to the second jig-surface and that is non-perpendicular to the first jig-surface such that each one of the holes formed in the workpiece has a hole axis that is non-perpendicular to the workpiece-surface.

A double eccentric positioning apparatus uses two equal offset eccentric bushings to accurately position a tool (such as a drill bushing) in two dimensions. Miniature servo motors and precise gearing control the rotation of each eccentric bushing, which controls the direction of the offset vectors. The offset vectors are used to determine the final position of the drill bushing. The desired rotation angles can be mathematically calculated based on desired position. The inner eccentric bushing is located concentric to the offset of the outer eccentric bushing. This allows any position, within a radius of two times the eccentric offset, to be achieved. The use of worm gearing on the eccentric bushings prevents back-driving of the servo motors, due to the lead angle of the worm gears, and the friction between the worm wheel and worm gear.

A drill block and a method for drilling a hole through a workpiece using the drill block. The drill block may include a mounting leg for mounting the drill block, a drilling support leg having a round hole therethrough operable to receive a drill bit during a drilling operation, and a height variability leg interposed between the mounting leg and the drilling support leg, wherein the height variability leg is adjustable to select a vertical height of the drilling support leg relative to the mounting leg.

A wing skin, which was secured to a wing structure by a plurality of fasteners extending through the wing skin, is removed from the wing and aligned with a template. Template holes are drilled through the template corresponding to each of the fastener holes of the wing skin. The template is then aligned with a new wing skin, and pilot holes are drilled through the new wing skin corresponding to each of the template holes. The new wing skin is then aligned with the wing structure such that the pilot holes permit access to corresponding fastener holes of the wing structure. A mill bit is then positioned through each pilot hole and aligned with the center of the corresponding consumable bushing in the fastener hole of the wing sub-structure, and the skin pilot holes are milled to form fastener holes in the new wing skin aligned with existing sub-structure.

A double eccentric positioning apparatus uses two equal offset eccentric bushings to accurately position a tool in two dimensions. Miniature servo motors and precise gearing control the rotation of each eccentric bushing, which controls the direction of the offset vectors. The offset vectors are used to determine the final position of the drill bushing. The desired rotation angles can be mathematically calculated based on desired position. The inner eccentric bushing is located concentric to the offset of the outer eccentric bushing. This allows any position, within a radius of two times the eccentric offset, to be achieved. The use of worm gearing on the eccentric bushings prevents back-driving of the servo motors, due to the lead angle of the worm gears, and the friction between the worm wheel and worm gear.

A drill guide includes a shaft, a drill guide assembly securable to the shaft, and a first drill guide insert. The drill guide assembly includes a first drill guide body defining a receiving passage, a locking member, and terminating in a first grasping projection that flexes between open and closed positions. The first drill guide insert installs in the receiving passage and includes a bore, a grasping projection displacement surface, a locking groove, and a key member. The grasping projection displacement surface moves the first grasping projection from its closed position to its open position during installation of the first drill guide insert. Upon installation, the locking groove receives the first grasping projection to lock the first drill guide insert in the first drill guide body, and the key member engages the locking member to prevent rotation of the first drill guide insert within the first drill guide body.

A bushing for a drill template, the bushing has a head portion for receipt of a drill motor. The head portion has a top surface and a bottom surface with at least one pin protruding from the bottom surface of the head portion. The pin fits within a secondary opening in a template to help retain the bushing in place. A body portion extends from the bottom surface of the head portion. The body portion has an outer surface with a portion of it threaded. The body portion extends through a primary drill hole in the template. A fastening nut having inner threads mates with the outer threads on the body portion to lock the bushing to the template. A bore extends through the head portion and the body portion for receipt of a drill bit.