I need a tool and ideas for an aircraft issue

[f4 plt]

My local IA ( inspection authority) has challenged me to come up with a solution to a problem. I have a neighbor with a M35 (1960) Bonnza and the pliable fiber duct that goes from the back of the air filter assembly to the on which the air intake plenum has deteriorated and must be removed and replaced . It is attached with eight screws (Phillips head) the lower six are not easy but can be removed with patience. The upper two are hidden behind the cross brace for the front engine mount. To make matters there is only about 1 inch of clearance. Additionally the intake plenum adds another restriction. So the question

who has ideas on how to get them out. I need a minimum clearance racket that it can insert a very short Phillips head screw driver bit into. Ideas are most welcome . Thanks

 

[toolman9w]

https://www.grainger.com/product/3ZH36?cm_mmc=PPC:+Google+PLA&s_kwcid=AL!2966!3!219726178498!!!g!356585828113!&ef_id=WljsewAAAGDlX0sY:20180123001058:s&kwid=productads-adid^219726178498-device^c-plaid^356585828113-sku^3ZH36-adType^PLA

Or similar. I googled bit ratchet

 

[AE2]

Gearwrench microdriver
https://www.amazon.com/GearWrench-85035-35-MicroDriver-Set/dp/B0062FSAVI

 

[BolognaBlake]

Gearwrench microdriver
https://www.amazon.com/GearWrench-85035-35-MicroDriver-Set/dp/B0062FSAVI

That's what I would use.

I have the same kit, though mine is Husky branded.

 

[Alchymist]

$10 at Lowes.
https://www.lowes.com/pd/Kobalt-24-...ic-Mechanic-s-Tool-Set-with-Hard-Case/3387782

 

[L.Cheapo]

https://store.snapon.com/Low-Profile-Screwdrivers--2-PHILLIPS-reg-Tip-P794487.aspx

You'd be hard pressed to get lower profile than that. Yes, I know someone else makes it for Snappy, but $16 delivered to your door isn't too bad.

 

[AE2]

$10 at Lowes.
https://www.lowes.com/pd/Kobalt-24-...ic-Mechanic-s-Tool-Set-with-Hard-Case/3387782

For the OP’s purpose the Kobalt should work. I have the Gearwrench and the Kobalt and the Gearwrench has a better ratchet mechanism, socket adapters and sockets.

 

[AE2]

Bostitch version
https://www.menards.com/main/p-1503642937428-c-9158.htm?tid=6943445094188880200&ipos=2

 

[Ole Slewfoot]

Offset screwdriver.

 

[619DioFan]

That's what I would use.

I have the same kit, though mine is Husky branded.

I have the husky version as well. works great.

 

[Alchymist]

https://store.snapon.com/Low-Profile-Screwdrivers--2-PHILLIPS-reg-Tip-P794487.aspx

You'd be hard pressed to get lower profile than that. Yes, I know someone else makes it for Snappy, but $16 delivered to your door isn't too bad.

I have several of that type, they work well, however I find the Kobalt set more versatile and easier to use. JMHO.

 

[f4 plt]

Offset screwdriver.

Tried one clearance issues. From the screw he’d when fully seated to thebulkhead behind that limits clearance is about I inch and the screw is just over 1/4 inch long so I don’t have much room . The bulkhead / bracket prevents using a normal screwdriver and being a structural member I can’t cut a notch in it ... this duct is designed to be replaced with engine removed

 

[ca90ss]

https://store.snapon.com/Low-Profile-Screwdrivers--2-PHILLIPS-reg-Tip-P794487.aspx

You'd be hard pressed to get lower profile than that. Yes, I know someone else makes it for Snappy, but $16 delivered to your door isn't too bad.

For that price you can get the whole set
https://www.amazon.com/Anex-6102T-Profile-Driver-Handle/dp/B0016VAIBI/ref=sr_1_1?ie=UTF8&qid=1516670682&sr=8-1&keywords=anex+6102t+ultra+low+profile+screw+driver+handle

Other options
https://store.snapon.com/Stubby-Bits-and-Bit-Holder-For-Low-Profile-Ratchets-Bit-Stubby-Phillips-2-P650278.aspx

https://www.tooltopia.com/vim-vhc77.aspx

 

[pepi]

Top tool has a ratchet action, the tab to the RH changes the direction. The phillips and common bit is fixed, none removable.

The bottom tool shown above, allows bits of any style to be used. The tool must be flopped to change directions.

Here is the advantage, once the OP removes the fillips, he can replace the phillips with a 1/4 hex head screws, think gear wrench 1/4 in.

Greg

 

[Kenstone1]

You need a reversible squeeze ratchet
https://www.amazon.com/dp/B000K1NXGW/?tag=atomicindus08-20
Not available though...

Chapmen makes a set of 1/4" hex bits that come with a small/thin 1/4" hex ratchet.
Because it is turned over to reverse, it can be wedged into a confined space when backing out a screw with no way to reverse it/get it out, ask me how I know
Chapmen Set:
https://www.amazon.com/dp/B00T34D8GW/?tag=atomicindus08-20

I have a similar one that is reversible but cannot get to it now to find out who makes it.
Here's a thin/reversible 1/4" hex ratchet that might work, I have 3, one straight, 2 offset:
https://www.amazon.com/dp/B0748DCVHN/?tag=atomicindus08-20

Edit: a simple solution would be turn a Philips 1/4" hex bit with a 1/4" ignition wrench, done that before.

 

[M6erfan]

https://store.snapon.com/Low-Profile-Screwdrivers--2-PHILLIPS-reg-Tip-P794487.aspx

You'd be hard pressed to get lower profile than that. Yes, I know someone else makes it for Snappy, but $16 delivered to your door isn't too bad.

These are about the lowest profile you'll find. Also, they're rebranded Anex (Japan) so you should be able to find them cheaper than S-O.

Edit: matter of fact...3 for less $ than 1 S-O;

https://www.amazon.com/Anex-6102T-Profile-Driver-Handle/dp/B0016VAIBI/ref=pd_sim_469_1?_encoding=UTF8&pd_rd_i=B0016VAIBI&pd_rd_r=ECCZF0QJT61235XBEP3C&pd_rd_w=jnwpO&pd_rd_wg=FQ5sf&psc=1&refRID=ECCZF0QJT61235XBEP3C

 

[L5wolvesf]

Gearwrench microdriver
https://www.amazon.com/GearWrench-85035-35-MicroDriver-Set/dp/B0062FSAVI

I second this. This is my go to when dealing with really tight spots. Credit to my g/f she got them for me I didn't know they existed.

 

[p_mori7]

If the pliable duct needs to be replaced, cut it off close to the screws then twist them out from the inside with vise-grips or drill them out ?

Maybe I'm not visualizing the issue properly.

Could the engine mounts be loosened to gain some more clearance ?

 

[Lassen Forge]

These are about the lowest profile you'll find. Also, they're rebranded Anex so you should be able to find them cheaper than S-O.

Edit: matter of fact...3 for less than one S-O;

https://www.amazon.com/Anex-6102T-Profile-Driver-Handle/dp/B0016VAIBI/ref=pd_sim_469_1?_encoding=UTF8&pd_rd_i=B0016VAIBI&pd_rd_r=ECCZF0QJT61235XBEP3C&pd_rd_w=jnwpO&pd_rd_wg=FQ5sf&psc=1&refRID=ECCZF0QJT61235XBEP3C

This. I'd ask your A&P guy what he'd (or she'd) do... stuff like this perplexes normal immortals like us, but it's likely he's seen this before.

The one thing you do NOT want to do is fubar your planes certification if you do it wrong... I was (honestly) thinking a Phillips bit and a long (I think it's 1/4") gearwrench for the ratchet action. You might even (depending on your access issues) have to use a heat wrench to add a handle extension, then bend it, to get to where you gotta go...

But there has to be an easier way, and if anyone's seen it, it's the guys and gals who inspect and fix GA aircraft for a living...

(The cool thing is once you get your modified part cerificated and patented, you may have a niche part that can pay for a number of $250 hamburgers!)

 

[22george]

I worked on large aircraft for 30 years. We shortened the phillips screwdriver bit and welded a handle- steel bar- on the side of it. Used it when had clearance issues for years.