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post #23 of Old 07-20-2012
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Re: Pad eyes for tethers and jacklines

It takes a jig saw with a metal cutting blade, but doesn't take anything special. Carbide blades of course make it easier, but aren't necessary. Drills about like thickened epoxy, so sharp bits and medium preassure, just keep the bit cutting, anymore is unhelpful, any less and you can scorch the bit.

I typically use 1/4" for everything, except where weight is a major concern (unless you have paid for carbon fiber everything weight isn't a big enough concern to worry about here). I would trace the size of the pad eye then add about 1/2" to the profile and cut to that. I also like to knock down the endges with a file or rasp before installing Epoxy and bolt it into place and it will last forever.

Like I said technically you can tap it for the fasteners, but I just don't trust threads tapped into FRP, so I always go with washers and nuts unless there is a specific reason I can't

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