Ok, it''s not exactly a Hollywood Blockbuster but we think it's pretty
cool. Space Shuttle seemed like a cursed PF.
The original holes were cut slightly too small which meant none of the
inserts fit. Each and every PF had to have each and every insert hole
and GI bulb hole sanded out by hand using a dremel. We went through
nearly 400 3/8" little sanding drums! Then we had many of the lips the
inserts sit on cut to the incorrect depth, too deep and the inserts
slipped below the surface and had to be removed and replaced. Too high
and the drum sander basically sheared them off and they had to be
removed and replaced. Lots and lots of removing and replacing! There
were hundred of inserts that had to be replaced along the way and that
was after each and every hole had to be size corrected!! In all there
were hundreds of hours spent fixing these cutting errors. But the
nice thing is that we have encountered all these problems before on
previous PFs but other than Flight 2000 we had never seen these
problems in these numbers! Our past experience allows us to repair
almost anything that happens to a PF because, well because you have
to. The wood is dear and the inserts that are glued in properly cannot
easily be replaced from the maker so you MUST fix the PFs or lose
them.
Anyway they turned out SWEET!
Mike
http://www.youtube.com/watch?v=eVgBeXamc2w