WESCON DSI DESIGNED SOLUTIONS INCORPORATED AIRFRAME ASSEMBLY TOOLS AND RELATED SERVICES PHONE 949.444.3807 / FAX 949.916.0236
20551 PASCAL WAY LAKE FOREST, CA 92630 USA "DESIGNED SOLUTIONS" With over thirty-five years of helping our customers solve issues encountered in the manufacture and assembly of Airframes of all types, we feel uniquely qualified to provide solutions for the challenges of producing today's advanced airframes. Our products have been developed from both industry standards, as well as specific customer requirements. We will continue to add to our product line based on the needs of our customers, and always welcome unique inquiries to solve specific problems.
CONTENTS MICROSTOP UNITS PG 1-5 GAGING SYSTEMS PG 6 FASTENER REMOVAL TOOLS COLLET TYPE & QUICK CHANGE CHUCKS PG 7 & 8 PG 9 SPECIAL ORDER DRILL GUIDES PG 10 NOTES
MODELS 296 & 396 MICROSTOP UNIT MODEL 296 10000 RPM DUAL BALL BEARING SYSTEM.001 DEPTH ADJUSTMENT 1/8 STROKE & SOLID STOP 5/8 CUTTER CAPACITY 1/4-28 ID THREADED SHAFT 1/4-28 THREADED SHANK (-TS) OR QUICK CHANGE (-QC) AVAILABLE WITH OR WITHOUT ANTI-ROTATION PIN (-AR) OPTIONAL SKIRTS & FOOT PIECES AVAILABLE 296-S-TS 296-S-TS-AR MODEL 396 10000 RPM DUAL BALL BEARING SYSTEM.0005 DEPTH ADJUSTMENT 1/8 STROKE & SOLID STOP 1/2 CUTTER CAPACITY 1/4-28 ID THREADED SHAFT 1/4 STRAIGHT SHAFT OR QUICK CHANGE (-QC) OPTIONAL SKIRTS & FOOT PIECES AVAILABLE 396-S PAGE 1
MODEL 596 MICROSTOP UNIT HIGH SPEED HEAVY DUTY 10,000 RPM DUAL BALL BEARING SYSTEM HEAVY DUTY THRUST BEARING.0005 INCREMENTAL ADJUSTMENT.300 STROKE & SOLID STOP INTEGRATED DUST SEAL 1/4-28 ID THREADED SHAFT 1/4 DIAMETER SHANK OPTIONAL SHAFTS TRI-FLATS (-TF) QUICK CHANGE (-QC) 596-S STRAIGHT SKIRT (3/4 CUTTER CAPACITY) 596-F FLANGE SKIRT (3/4 CUTTER CAPACITY) 596-EN NYLON FOOT 596-ES STEEL FOOT (3/4 CUTTER CAPACITY) 596-IN NYLON FOOT (5/8 CUTTER CAPACITY) 596-B BELL SKIRT (7/8 CUTTER CAPACITY) 596-BEN NYLON FOOT 596-BES STEEL FOOT (7/8 CUTTER CAPACITY) PAGE 2
MODEL 596-ER SERIES MICROSTOP UNIT 2.00 1.25.688 596-ER1 (1/2 CUTTER CAP.).500 596-ER3 (3/8 CUTTER CAP.) EXTENDED REACH UNITS 2.75 2.75 10,000 RPM DUAL BALL BEARING SYSTEM HEAVY DUTY THRUST BEARING.0005 INCREMENTAL ADJUSTMENT.300 STROKE & SOLID STOP INTEGRATED DUST SEAL 1/4 DIAMETER SHANK OPTIONAL SHAFTS TRI-FLATS (-TF) QUICK CHANGE (-QC).500 596-ER5 (3/8 CUTTER CAP.).375 596-ER8 (1/4 CUTTER CAP WITH 10-32 THREAD.) 2.75.425 596-ER9 (5/16 CUTTER CAP.) PAGE 3
MODEL 596-ES SERIES MICROSTOP UNIT EXTENDED STROKE UNITS FOR DRILL / COUNTERSINK AND SPECIAL LENGTH CUTTERS 10,000 RPM DUAL BALL BEARING SYSTEM HEAVY DUTY THRUST BEARING.0005 INCREMENTAL ADJUSTMENT EXTENDED STROKE & SOLID STOP 5/8 DIAMETER CUTTER CAPACITY 1/4-28 ID THREADED SHAFT 1/4 DIAMETER SHANK 596-ES-1000 (1.00 STROKE) 596-ES-750 (.750 STROKE) 596-ES-500 (.500 STROKE) PAGE 4
MODEL 696 SERIES MICROSTOP UNIT LARGE CAPACITY UNITS 10,000 RPM DUAL BALL BEARING SYSTEM & INTEGRATED DUST SEAL HEAVY DUTY THRUST BEARING - 1/2 STROKE & SOLID STOP.0005 INCREMENTAL ADJUSTMENT 3/8 DIA. ROUND SHAFT STANDARD 3/8-24 INTERNAL THREAD STANDARD STANDARD MODELS MODEL NO. CUTTER CAPACITY 696-875 7/8 696-1000 1" 696-1250 1-1/4" 696-1375 1-3/8" 696-1500 1-1/2" SHAFT OPTIONS TRI-FLAT SHANK (-TF) 7/16-20 INTERNAL THD (-4320) OPTIONAL SKIRT CONFIGURATIONS AND FOOT PIECES ALSO AVAILABLE PAGE 5
GAGING SYSTEMS COUNTERSINK MEASURING SYSTEM MODEL 5730-1-100 KIT OTHER STYLES CAN BE CONFIGURED TO CONFORM TO CUSTOMERS FASTENER SPECIFICATIONS INTERCHANGEABLE POINTS FOR MEASURING FLUSHNESS OR COUNTERSINK DEPTH DIMENSION (THIS KIT INCLUDES POINTS FOR A WIDE RANGE OF SIZES FOR 100 DEGREE RIVETS AND COLLAR TYPE FASTENERS) SKIRT FOR SMALLER DIAMETER FASTENERS AND CLOSE QUARTERS THREE FOOT SKIRT FOR CONTOUR SURFACES DIGITAL GAGE WITH MICROSTOP ADJUSTABLE BASE INSTRUCTIONS FOR USE MEASURING FASTENER HEAD FLUSHNESS WITH SURFACE Utilizing one of the three supplied "FLUSH POINTS", FP-250, FP-313 or FP-375, install it allowing the point to protrude slightly past the face of the foot piece. Place the Gage on the skin surface in an unobstructed area and Zero out the Gage by pressing the "SET" button. Then, by placing the Point on the top of the fastener head the gage will indicate whether the head is flush, giving a "0" reading, above, giving a "+" reading, or below, giving a "-" reading. MEASURING TO THE DESIRED COUNTERSINK CUT DEPTH Install the proper "MEASURING POINT" for size and style of fastener you will be installing. Adjust the Gage so the point's angled portion protrudes past the face of the foot piece. Next, set the display on the Indicator to read minus, "-", the desired number for the depth of the countersink cut. Then, by locating the Point in the countersink cut, the gage will display either a "0" reading, indicating it is at the desired depth, a "+" reading indicating it is not deep enough, or a "-" reading, showing that it is deeper than desired. MEASURING ACTUAL COUNTERSINK CUT DEPTH Install the proper "MEASURING POINT" for size and style of fastener you will be installing. Adjust the Gage so the point's angled portion protrudes past the face of the foot piece. Place the gage on the skin in an unobstructed area and Zero out the Gage by pressing the "SET" button. Then, by locating the Point in the countersink cut, the gage will indicate the actual depth of the cut. PAGE 6
FASTENER REMOVAL TOOLS MICROSTOP AND LOCATING INSERTS FOR PROTRUDING HEAD FASTENERS MODEL 497 MICROSTOP UNIT MODEL 4970-1 KIT INCLUDES ALL ITEMS ON THIS PAGE (All items can also be ordered separately) DEPTH CONTROL SKIRT CUTTER LOCATING INSERT LOCKING RING SKIN PANEL INSTALLED FASTENER PART NO. 4971 THREADED SHANK DRILL KIT PART NO. 4972 COLLAR CUTTER KIT PART NO. FASTENER TO REMOVE PART NO. CUTTER SIZE / FASTENER TO REMOVE TSD-#50 3/32 FASTENER HC-1.365 DIA. X.125 HOLE - 1/8 FASTENER TSD-#40 1/8 FASTENER HC-2.365 DIA. X.156 HOLE - 5/32 FASTENER TSD-#30 5/32 FASTENER HC-3.438 DIA. X.187 HOLE - 3/16 FASTENER TSD-#20 3/16 FASTENER HC-4.500 DIA. X.250 HOLE - 1/4 FASTENER TSD-#1 1/4 FASTENER PART NO. 4973 INSERT KIT FOR UNIVERSAL HEAD RIVETS PART NO. 4974 INSERT KIT FOR PROTRUDING HEAD THREADED FASTENERS PART NO. 4975 INSERT KIT FOR COLLARS PART NO. RIVET SIZE / TYPE PART NO. FASTENER SIZE / TYPE UHR-2 3/32 UNIVERSAL HEAD RIVET PSH-5 5/32 PROTRUDING SHEAR HEAD UHR-4 1/8 UNIVERSAL HEAD RIVET PSH-6 3/16 PROTRUDING SHEAR HEAD UHR-5 5/32 UNIVERSAL HEAD RIVET PSH-8 1/4 PROTRUDING SHEAR HEAD UHR-6 3/16 UNIVERSAL HEAD RIVET UHR-8 1/4 UNIVERSAL HEAD RIVET PTH-5 5/32 PROTRUDING TENSION HEAD PTH-6 3/16 PROTRUDING TENSION HEAD PTH-8 1/4 PROTRUDING TENSION HEAD PART NO. COLLAR SIZE / TYPE HLC-5 5/32 THREADED COLLAR HLC-6 3/16 THREADED COLLAR HLC-8 1/4 THREADED COLLAR LBC-6 3/16 SWAGED COLLAR LBC-8 1/4 SWAGED COLLAR PAGE 7
FASTENER REMOVAL TOOLS VACUUM LOCATING FIXTURE FOR FLUSH FASTENERS THESE FIXTURES ARE USED TO LOCATE THE CENTER OF A FLUSH HEAD FASTENER UTILIZING A TOOLING STYLE "BOMB SIGHT". ONCE LOCATED, THE FIXTURE IS LOCKED IN PLACE AND THE "BOMB SIGHT" IS REPLACED WITH A SLIP RENEWABLE DRILL BUSHING TO GUIDE THE DRILL THROUGH THE CENTER OF THE FASTENER HEAD. MODEL 5850-1 KIT INCLUDES ALL ITEMS ON THIS PAGE MODEL 5854-115 CLOSE QUARTERS ATTACHMENT MODEL 5854 TRI-CUP FIXTURE FEATURES THREE SUCTIONS CUPS TO LOCATE ON LARGER SURFACES. MODEL 5855 DONUT FIXTURE FEATURES A DONUT STYLE SUCTION CUP TO LOCATE IN TIGHTER AREAS. MODEL 5858 OPTICAL BOMB SIGHT MODEL 5855-115 3/16 CLOSE QUARTERS ATTACHMENT 1/4 FASTENER SLIP RENEWABLE SIZE BUSHINGS DRILL BITS 3/32 SF-32-8-.070 #50 ID SMD-#50 1/8 SF-32-8-.098 #40 ID SMD-#40 5/32 SF-32-8-.1285 #30 ID SMD-#30 SF-32-8-.1610 #20 ID SMD-#20 SF-32-8-.2280 #1 ID SMD-#1 MODEL 5856 VACUUM GENERATOR INCLUDES IT'S OWN VACUUM CUP, FOR SECURING ITSELF IN PLACE, A SLIDE VALVE AND HOSES. WESCON DSI 949.444.3807 / 949.916.0236 PAGE 8
THREADED & QUICK CHANGE SHANK COLLET CHUCKS MODEL 1605-1/4 MODEL 1625-1/4 OUR EXCLUSIVE 120 DEGREE SEATING ANGLE PROVIDES SUPERIOR CONCENTRICITY USED WITH 1/4-28 THREADED ANGLE DRILL MOTORS. STANDARD SERIES FOR USE IN WITH OUR MODEL 1750 CHUCK 7/16 HEX 1/2 HEX QUICK CHANGE CHUCKS MODEL 1750 STANDARD SERIES 3/8-24 FEMALE THREAD TO FIT MOST DRILL MOTORS MODEL 1760 SHORT SERIES 1/4-28 MALE THREAD 120 DEGREE SEAT ANGLE TO FIT MOST RIGHT ANGLE TYPE DRILL MOTORS PAGE 9
SPECIAL ORDER DRILL GUIDES USE TO GUIDE DRILL IN HAND HELD DRILLING APPLICATIONS MADE OF ANODIZED ALUMINUM FOR DURABILITY FOR USE WITH "SF STYLE DRILL BUSHINGS (DRILL BUSHINGS SOLD SEPARATELY) "EGG CUP" STYLE DRILL GUIDE "PULL TYPE" DRIIL BARS DRILL GUIDES "DOG BONE" STYLE DRILL GUIDE PAGE 10
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