As a few people have expressed interest in how I do my flight pegs. Here is my method. I know a lot of you have found your own answer to this, but I do them like this.
The material I use is plastic flight pegs from Litco as they are the cheapest way to get the machinable acrylic.
I turn these from 3mm to 2.5mm on the lathe and then put on a 1 degree taper until the official peg fits snugly.
Cut off with a parting tool or small hacksaw. Then sand down the end until it bottoms into the hole in the plane, leaving the protrusion that you require.(This may vary for different aircraft setups.)
To drill out for the hole in the plane I use a drill press and hand vice. You will see that the body of the aircraft is protected by a folded paper towel to stop the jaws of the vice marking the soft metal. Set the drill stop to the required depth and check for squareness in all directions. I use a small 2mm pilot drill first and then the 2.5mm to size the hole.
NB. It is called a pilot hole because if it comes out through the pilots head, you know that you have set up the depth stop wrongly.
Rob.
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