The method of locating hole features so that old components can be replaced with new components and still match fit with the airframe includes the steps of adhering a bushing assembly into a fixture plate, rigidly attaching the fixture plate with the bushing assembly to the old component, heating the liquid metal above the liquid metal melting temperature such that the cylindrical drill bushing can move within the assembly, inserting an alignment pin within the cylindrical drill bushing such that the alignment pin is also inserted into an existing hole in the old component and the airframe, allowing the liquid metal to re-solidify; removing the alignment pin from the old component, replacing the old component with the new component, and using the re-solidified assembly as a drill guide for replacing holes in the new component.

A method for forming drilled cast which includes drilling with a drill so as to provide communication with a cast hole includes a casting step and a drilling step. The casting step is to cast a cast having a cast hole which includes a flat inner wall surface in which width of a position to be drilled with the drill is obtained by adding first length H1 serving as a manufacturing error range of the cast to a diameter D of the drill, which is a second length H2. The drilling step is to form a through hole providing communication between an interior of the cast hole and an exterior of the cast through the flat inner wall surface with the drill.

The reusable liquid metal castable drill bushing assembly for use in a fixture plate includes a cylindrical sleeve having an inner diameter, a cylindrical drill bushing having an outer diameter, a liquid metal disposed between the outer diameter of the cylindrical drill hushing and the inner diameter of the cylindrical sleeve, a seal disposed on the cylindrical sleeve, the cylindrical drill bushing, and the liquid metal such that the seal retains the liquid metal between the outer diameter of the cylindrical drill bushing and the inner diameter of the cylindrical sleeve.

A spindle assembly for machining a cast workpiece includes a fixture that provides rotational movement to the workpiece around a fixture axis. A first spindle provides rotational movement to a cutting tool around a first spindle axis and a second spindle provides rotational movement to a second cutting tool around a second spindle axis. The first spindle axis and the second spindle axis are transverse to the fixture axis. The fixture is disposed between the first spindle and the second spindle. The pivotal movement of the fixture provides access to opposite sides of the workpiece to the first spindle and the second spindle enabling the cutting tools to simultaneously cut opposing sides of the workpiece. The first cutting tool and the second cutting tool are replaceable by a third cutting tool and a fourth cutting tool to cut an alternative or different aperture into the workpiece.

A spindle assembly for machining a cast workpiece includes a fixture that provides rotational movement to the workpiece around a fixture axis. A first spindle provides rotational movement to a cutting tool around a first spindle axis and a second spindle provides rotational movement to a second cutting tool around a second spindle axis. The first spindle axis and the second spindle axis are transverse to the fixture axis. The fixture is disposed between the first spindle and the second spindle. The pivotal movement of the fixture provides access to opposite sides of the workpiece to the first spindle and the second spindle enabling the cutting tools to simultaneously cut opposing sides of the workpiece. The first cutting tool and the second cutting tool are replaceable by a third cutting tool and a fourth cutting tool to cut an alternative or different aperture into the workpiece.

A method for forming drilled cast which includes drilling with a drill so as to provide communication with a cast hole includes a casting step and a drilling step. The casting step is to cast a cast having a cast hole which includes a flat inner wall surface in which width of a position to be drilled with the drill is obtained by adding first length H1 serving as a manufacturing error range of the cast to a diameter D of the drill, which is a second length H2. The drilling step is to form a through hole providing communication between an interior of the cast hole and an exterior of the cast through the flat inner wall surface with the drill.