Abstract:
A method for forming a plurality of aligned holes includes aligning a first surface defining a first hole with a second surface defining a second hole, wherein the first hole at least partially aligns with the second hole to form a gap. A virtual hole diameter is measured, wherein the virtual hole diameter is a diameter of a virtual hole through the gap and the virtual hole diameter is a smallest bisector of the gap. Responsive to the virtual hole diameter having a first virtual hole diameter, a first cleanup hole having a first cleanup hole diameter is formed through the gap, wherein the first cleanup hole is concentrically aligned with the virtual hole. A first fastener having a first size is inserted into the first cleanup hole, and the first surface is attached to the second surface using the first fastener. Additional implementations are described.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. application Ser. No. 14/497,278, filed Sep. 25, 2014 and issued Feb. 21, 2017, as U.S. Pat. No. 9,573,209, the disclosure of which is incorporated herein by reference in its entirety. 
     
    
     BACKGROUND 
       [0002]    Field 
         [0003]    Devices and methods are disclosed for producing aligned holes from misaligned holes. More particularly, systems and methods are disclosed for determining the size of a fastener to be used and for producing aligned holes from the misaligned holes. 
         [0004]    Background 
         [0005]    When multiple objects are to be connected together, fasteners of various sizes are commonly used. A circular hole is then drilled into each object, and ideally the objects are then placed next to one another such that the respective holes in the objects overlap each other and circumferences of the holes align. For the purposes hereof, when two or more such holes overlap with one another, the passageway through the holes is referred to as the gap. The virtual hole diameter of the gap is defined as the bisector of the gap with the smallest length. As will be understood, it is the length of the smallest bisector through the gap which determines whether a given fastener will fit through the (mis)aligned holes. Presuming the holes in the objects align properly, the gap should have the same shape as either of the holes, such that the virtual hole diameter of the gap is equal to the diameter of either hole. This is because with aligned holes, all bisectors of the gap have the same length, which is equal to the diameter of either hole. A fastener which would fit through either of the holes should therefore fit through the gap defined by the aligned holes as well, so as to secure the objects together. 
         [0006]    However, a hole in one of the objects may not align properly with the corresponding hole in the other object when the objects are brought together. Misalignment of the holes reduces the size of the resulting gap through the objects, and specifically results in a gap in which the shortest bisector is shorter than the diameter of either original hole. Thus, the misaligned holes result in a gap with a virtual hole diameter that is smaller than the diameter of either hole and that could potentially be too small for the intended fastener to fit therethrough. As will be understood, a virtual hole that has a diameter equal to the virtual hole diameter is theoretically the diameter of the largest fastener which would fit through a misaligned set of holes. 
         [0007]    A common technique for correcting misaligned holes is to drill or ream a cleanup hole through the misaligned holes, centered on one of the misaligned holes. A cleanup hole is preferably large enough in diameter that all of the misaligned holes fit fully within the cleanup hole, such that nothing of the original misalignment remains. Once the cleanup hole has been created, a fastener—which may also have a larger diameter than the diameter of the originally intended fastener—is placed through the cleanup hole to secure the objects together. 
         [0008]    Conventionally, cleanup holes are created on a trial-and-error basis. Progressively larger and larger diameter cutters are used to incrementally remove minimal amounts of material from the misaligned holes. Multiple sizes of go/no-go gages and visual inspection are used to determine whether the newly-created cleanup hole meets fastener installation requirements. This trial-and-error method involves an element of subjectivity and is labor intensive. Special drill jigs are clamped to two or more adjacent holes or surfaces and are adjusted to center on the near-side misaligned hole. Not only is this process time consuming, but also requires a larger diameter hole to be produced to clean up the misaligned holes. 
       SUMMARY 
       [0009]    According to one embodiment, a method for forming a plurality of aligned holes includes aligning a first surface defining a first hole with a second surface defining a second hole, wherein the first hole at least partially aligns with the second hole to form a gap, and measuring a virtual hole diameter, wherein the virtual hole diameter is a diameter of a virtual hole through the gap and the virtual hole diameter is a smallest bisector of the gap. The method further includes, responsive to the virtual hole diameter having a first virtual hole diameter, forming a first cleanup hole having a first cleanup hole diameter through the gap, wherein the first cleanup hole is concentrically aligned with the virtual hole, inserting a first fastener having a first size into the first cleanup hole, and attaching the first surface to the second surface using the first fastener. 
         [0010]    The method may further include, responsive to the virtual hole diameter having a second virtual hole diameter that is larger than the first virtual hole diameter, forming a second cleanup hole having a second cleanup hole diameter that is larger than the first cleanup hole diameter through the gap, wherein the second cleanup hole is concentrically aligned with the virtual hole, inserting a second fastener having a second size into the second cleanup hole, wherein the second size is larger than the first size, and attaching the first surface to the second surface using the second fastener. 
         [0011]    In an embodiment, responsive to the virtual hole diameter being equal to at least one of a first hole diameter of the first hole and a second hole diameter of the second hole, the method may further include inserting a third fastener having a third size into the virtual hole without forming a cleanup hole through the gap, wherein the third size is smaller than the first size, and attaching the first surface to the second surface using the third fastener. The method may additionally include inserting a tapered reamer into the gap, the tapered reamer having a longitudinal axis and configured such that the longitudinal axis aligns with a center of one of the first cleanup hole or the second cleanup hole when the tapered reamer is inserted into the gap, and reaming the first surface and the second surface to form the one of the first cleanup hole or the second cleanup hole. The method may additionally include inserting a step gage into the gap to perform the measuring of the virtual hole diameter, the step gage including at least a first section and a second section, wherein the first section includes a first section diameter which indicates that the first cleanup hole having the first cleanup hole diameter is to be formed through the gap and a second section includes a second section diameter that is smaller than the first section diameter, the second section diameter indicating that the second cleanup hole having the second cleanup hole diameter is to be formed through the gap. 
         [0012]    The inserting of the step gage into the gap may further include inserting the step gage that further comprises a third section having a third section diameter that is larger than the first section diameter, the third section diameter indicating that no cleanup hole is to be formed through the gap. The inserting of the first fastener into the first cleanup hole may insert the first fastener having a first fastener diameter, the inserting of the second fastener into the second cleanup hole may insert the second fastener having a second fastener diameter that is larger than the first fastener diameter, and the inserting of the third fastener into the virtual hole may insert the third fastener having a third fastener diameter that is smaller than the first fastener diameter. Additionally, the aligning of the first surface with the second surface may align the first hole having first hole diameter with the second hole having a second hole diameter that is equal to the first hole diameter, and the third fastener diameter is equal to the first hole diameter, and the inserting of the third fastener may insert the third fastener having a third fastener diameter that is equal to the first hole diameter and to the second hole diameter. In an embodiment, measuring of the virtual hole may measure the virtual hole that is circular. 
         [0013]    In another embodiment, a method for forming a plurality of aligned holes includes aligning a first surface defining a first hole with a second surface defining a second hole, wherein the first hole at least partially aligns with the second hole to form a gap and measuring a virtual hole diameter, wherein the virtual hole diameter is a diameter of a virtual hole through the gap, the virtual hole is circular, and the virtual hole diameter is a smallest bisector of the gap. Responsive to the virtual hole diameter having a first virtual hole diameter, forming a first cleanup hole having a first cleanup hole diameter through the gap, wherein the first cleanup hole is concentrically aligned with the virtual hole, inserting a first fastener having a first size into the first cleanup hole, and attaching the first surface to the second surface using the first fastener. Responsive to the virtual hole diameter having a second virtual hole diameter that is larger than the first virtual hole diameter, a second cleanup hole having a second cleanup hole diameter that is larger than the first cleanup hole diameter is formed through the gap, wherein the second cleanup hole is concentrically aligned with the virtual hole. The method further includes inserting a second fastener having a second size into the second cleanup hole, wherein the second size is larger than the first size and attaching the first surface to the second surface using the second fastener. 
         [0014]    In an embodiment, the method may further include, responsive to the virtual hole diameter being equal to at least one of a first hole diameter of the first hole and a second hole diameter of the second hole, inserting a third fastener having a third size into the virtual hole without forming a cleanup hole through the gap, wherein the third size is smaller than the first size and attaching the first surface to the second surface using the third fastener. Additionally, the method may further include inserting a tapered reamer into the gap, the tapered reamer having a longitudinal axis and configured such that the longitudinal axis aligns with a center of one of the first cleanup hole or the second cleanup hole when the tapered reamer is inserted into the gap, and reaming the first surface and the second surface to form the one of the first cleanup hole or the second cleanup hole. Moreover, the method may further include inserting a step gage into the gap to perform the measuring of the virtual hole diameter, the step gage including at least a first section and a second section, wherein the first section includes a first section diameter which indicates that the first cleanup hole having the first cleanup hole diameter is to be formed through the gap, a second section includes a second section diameter that is smaller than the first section diameter, the second section diameter indicating that the second cleanup hole having the second cleanup hole diameter is to be formed through the gap, the step gage further includes a third section including a third section diameter that is larger than the first section diameter, the third section diameter indicating that no cleanup hole is to be formed through the gap, and the first fastener has a first fastener diameter. Additionally, the second fastener has a second fastener diameter that is larger than the first fastener diameter, the third fastener has a third fastener diameter that is smaller than the first fastener diameter, the first hole has a first hole diameter, the second hole has a second hole diameter equal to the first hole diameter, and the third fastener diameter is equal to the first hole diameter and to the second hole diameter. 
         [0015]    In another embodiment, a system for connecting at least two objects together includes a first tool for measuring a virtual hole diameter of a virtual hole, wherein the virtual hole includes a gap including a first hole through a first object misaligned with a second hole through a second object and the virtual hole is a smallest bisector of the gap, a second tool for forming a cleanup hole having a cleanup hole diameter through the first object and the second object, wherein the second tool is configured to remove a first portion of the first object and a second portion of the second object at the gap, and a fastener having a fastener diameter configured to be inserted into the cleanup hole, wherein the fastener diameter is larger than the virtual hole diameter and smaller than the cleanup hole diameter. 
         [0016]    In an embodiment, the first tool includes at least a first section including a first section diameter and a second section including a second section diameter and the first section diameter indicates that the cleanup hole having the cleanup hole diameter is to be formed through the gap and the fastener having the fastener diameter is to be inserted into the cleanup hole, wherein the first section diameter is smaller than the first fastener diameter. In an embodiment, the virtual hole is a first virtual hole, the gap is a first gap, the cleanup hole is a first cleanup hole, the cleanup hole diameter is a first cleanup hole diameter, the fastener is a first fastener, and the fastener diameter is a first fastener diameter. The system may further include a second fastener having a second fastener diameter that is larger than the first fastener diameter, the second section diameter indicates that a second cleanup hole having a second cleanup hole diameter is to be formed by the second tool through the first object and the second object, wherein the second cleanup hole is larger than the first cleanup hole, and the second section diameter further indicates that a second fastener having a second fastener diameter larger than the first fastener diameter is to be inserted into the second cleanup hole, wherein the second fastener diameter is larger than the first fastener diameter. 
         [0017]    In an embodiment, the first tool further includes a third section having a third section diameter, wherein the third section diameter is larger than the second section diameter and 
         [0018]    a fourth section having a fourth section diameter, wherein the fourth section diameter is larger than the third section diameter, wherein the first, second, third, and fourth sections are connected and extend in series along the longitudinal axis of the first tool. The first section and the second section of the first tool may be connected and extend in series along a longitudinal axis of the first tool. The second tool is a tapered second tool configured to be at least partially inserted into the gap and the second tool may include a longitudinal axis configured such that the longitudinal axis aligns with a center of the cleanup hole when the tapered second tool is inserted into the gap defined by the first hole and the second hole. The second tool may include or more flutes. 
         [0019]    The features, functions, and advantages that have been discussed can be achieved independently in various embodiments or may be combined in yet other embodiments further details of which can be seen with reference to the following description and drawings. 
         [0020]    These and other advantageous features will be in part apparent and in part pointed out herein below. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]    For a better understanding, reference may be made to the accompanying drawings in which: 
           [0022]      FIG. 1A  is a top plan view of aligned holes in overlapping objects. 
           [0023]      FIG. 1B-1D  illustrate examples of misaligned holes, in which the misalignment increases from  FIG. 1B  through  FIG. 1D . 
           [0024]      FIG. 2  illustrates a side elevation view of one example of a step gage according to an embodiment. 
           [0025]      FIGS. 3A-3D  illustrate side elevation views of the step gage of  FIG. 2  being inserted into the holes of  FIGS. 1A-1D , and  FIG. 3E  illustrates a fastener inserted into the cleanup hole securing two or more objects together. 
           [0026]      FIG. 4  illustrates a side elevation view of one example of a tapered reamer according to an embodiment. 
           [0027]      FIG. 5A  is a graph showing the relationship between the length of a reamer&#39;s taper and the degrees of taper. 
           [0028]      FIG. 5B  is a graph showing the relationship between the positional accuracy of a tapered reamer and the degrees of taper. 
           [0029]      FIG. 6  illustrates a flow chart for using a step gage and tapered reamer. 
       
    
    
       [0030]    While various modifications and alternative forms are envisioned, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description presented herein are not intended to limit to the particular embodiment disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope hereof as defined by the appended claims. 
       DESCRIPTION 
       [0031]    According to one embodiment, various views are illustrated in  FIGS. 1-6  and like reference numerals are being used consistently throughout to refer to like and corresponding parts for all of the various views and figures of the drawings. Also, please note that the first digit(s) of the reference number for a given item or part should correspond to the figure number in which the item or part is first identified. 
         [0032]    Apparatuses and methods for creating aligned holes are provided. A step gage may have at least two steps of different diameters. These different diameters are sized and shaped to inform the user as to the appropriately sized cleanup hole needed to fully clean up the gap remaining between overlapping holes when such overlapping holes are misaligned. Once a cleanup hole size has been determined, a tapered reamer may be used which can be manually aligned on the misaligned holes, rather than on the near-side misaligned hole. The tapered reamer effectively aligns itself during use on the misaligned holes. Thus, a jig need not be used, and the resulting cleanup hole can be smaller than cleanup holes made using conventional processes. Forming the cleanup hole through the misaligned holes is also referred to herein as “cleaning up” the misaligned holes, which means forming concentrically-aligned holes having the same center and diameter through the existing misaligned holes. 
         [0033]    One embodiment described herein teaches a step gage for determining a diameter of an appropriate cleanup hole. The details of the various embodiments can be better understood by referring to the figures of the drawing. Referring to  FIG. 1A , two objects, such as plates  105 ,  110 , are shown. Each plate  105 ,  110  includes a hole  107 ,  112  respectively, extending therethrough. Holes  107 ,  112  have a diameter approximately equal to an intended hole diameter (IHD). As shown in  FIG. 1A , the plates  105 ,  110  have been brought together such that holes  107 ,  112  form a gap  100 A therethrough. 
         [0034]    Both of holes  107 ,  112  have a diameter approximately equal to the IHD. Each such hole  107 ,  112  is sized to receive a fastener of a predetermined diameter therethrough. As will be understood, if either of the respective holes  107 ,  112  in the two plates  105 ,  110  have exactly the same diameter as the intended fastener, the fastener may not fit through gap  100 A even if the two holes  107 ,  112  are properly aligned. Therefore, the holes  107 ,  112  in the respective plates  105 ,  110  are typically drilled to have a diameter which is slightly larger than that of the intended fastener, although not so much larger that too much space would remain even with the intended fastener inserted therein. This is referred to as the least material condition of the holes  107 ,  112 . The least material condition of these holes is therefore the circumstance in which each hole  107 ,  112  has the largest diameter within tolerance, such that the least material remains within tolerance. 
         [0035]    As seen in  FIG. 1A , the holes  107 ,  112  in the two plates  105 ,  110  are properly aligned, such that the hole  112  is not discretely visible below hole  107 . All bisectors through gap  100 A have the same length, which is equal to the diameter of holes  107 ,  112 . Therefore, the gap  100 A has a virtual hole diameter (VHD) equal to the diameter of the holes  107 ,  112 . The creation of a cleanup hole may therefore be inappropriate. However, for the purposes hereof, the virtual hole diameter (VHD) and the diameter of the holes  107 ,  112  in  FIG. 1A  is equal to a first cleanup hole diameter. 
         [0036]    In  FIGS. 1B through 1D , the plates  105 ,  110  have been excluded for ease of reference.  FIG. 1B  illustrates holes  107 ,  112  as being slightly misaligned, such that the geometric center of hole  107  is spaced apart from the geometric center of hole  112 . Unlike gap  100 A in  FIG. 1A , gap  100 B in  FIG. 1B  has a shortest bisector, which is labeled VHD. As can be seen, the misalignment of the holes  107 ,  112  causes the VHD of the resulting gap  100 B to be smaller than the diameter of either of holes  107 ,  112 , (and thus smaller than the diameter hole associated with an intended fastener). A virtual hole  120 B having the VHD of gap  100 B is shown in phantom in  FIG. 1B . This virtual hole  120 B has a diameter (again, VHD) of the largest diametered circle which will fit within gap  100 B. 
         [0037]    Due to the misalignment of the holes  107 ,  112 , a second cleanup hole  115 B (also shown in phantom in  FIG. 1B ) may be created through the plates  105 ,  110  (not shown). Such second cleanup hole  115 B preferably fully encompasses the holes  107 ,  112 . A cleanup hole which does not fully encompass the holes  107 ,  112  is possible, but would result in a lower precision fit between the cleanup hole and the fastener. 
         [0038]      FIG. 1C  illustrates holes  107 ,  112  as being more misaligned than those shown in  FIG. 1B , such that the geometric center of hole  107  is spaced farther from the geometric center of hole  112  than in  FIG. 1B . Like gap  100 B in  FIG. 1B , gap  100 C in  FIG. 1C  has a shortest bisector, which is again labeled VHD. The VHD of gap  100 C is shorter than the VHD of gap  100 B, because the misalignment of holes  107 ,  112  is greater in  FIG. 1C  than in  FIG. 1B . As can be seen, the increased misalignment of the holes  107 ,  112  again causes the VHD of the resulting gap  100 C to be smaller than the diameter of either of holes  107 ,  112 . A virtual hole  120 C having the VHD of gap  100 C is shown in phantom in  FIG. 1C . This virtual hole  120 C has a diameter (again, VHD) of the largest diametered circle which will fit within gap  100 C. 
         [0039]    Due to the increased misalignment of the holes  107 ,  112  in  FIG. 1C , a third cleanup hole  115 C (also shown in phantom in  FIG. 1C ) may be created through the plates  105 ,  110  (not shown). Such third cleanup hole  115 C preferably fully encompasses the holes  107 ,  112 , and would therefore be larger in diameter than second cleanup hole  115 B, due to the increased misalignment of holes  107 ,  112 . 
         [0040]      FIG. 1D  illustrates holes  107 ,  112  as being even more misaligned than those shown in  FIG. 1C , such that the geometric center of hole  107  is spaced even farther from the geometric center of hole  112  than in  FIG. 1C . Like gap  100 C in  FIG. 1C , gap  100 D in  FIG. 1D  has a shortest bisector, which is again labeled VHD. The VHD of gap  100 D is shorter than the VHD of gap  100 C, because the misalignment of holes  107 ,  112  is greater in  FIG. 1D  than in  FIG. 1C . As can be seen, the increased misalignment of the holes  107 ,  112  again causes the VHD of the resulting gap  100 D to be smaller than the diameter of either of holes  107 ,  112 . A virtual hole  120 D having the VHD of gap  100 D is shown in phantom in  FIG. 1D . This virtual hole  120 D has a diameter (again, VHD) of the largest diametered circle which will fit within gap  100 D. 
         [0041]    Due to the additionally increased misalignment of the holes  107 ,  112  in  FIG. 1D , a fourth cleanup hole  115 D (also shown in phantom in  FIG. 1D ) may be created through the plates  105 ,  110  (not shown). Such fourth cleanup hole  115 D preferably fully encompasses the holes  107 ,  112 , and would therefore be larger in diameter than the third cleanup hole  115 C, due to the increased misalignment of holes  107 ,  112 . 
         [0042]      FIG. 2  illustrates an example step gage  200  in accordance with an embodiment. As shown, step gage  200  includes four sections or steps: a first section  205  having a first diameter  207 , a second section  210  having a second diameter  212 , a third section  215  having a third diameter  217 , and a fourth section  220  having a fourth diameter  222 . These four sections  205 - 220  extend in series along the longitudinal axis  230  of the step gage  200 . Sections  205 - 220  may be integrally formed of any suitable material including (but not limited to) metal, plastic, wood, etc. Alternatively, sections  205 - 220  may be formed separately and then connected together, for example by (but not limited to) welding, adhesive, etc. The diameters  207 - 222  of these four sections  205 - 220  are selected in order to inform a technician as to the whether the intended fastener size will fit within a gap defined by holes  107 ,  112 . If the intended size fastener will not fit within the gap, the step gage  200  will indicate the appropriate size cleanup hole diameter which will fully encompass both misaligned holes ( 105 B- 105 D,  110 B- 110 D) and which will accept a fastener therethrough. 
         [0043]    When attempting to determine the diameter of an appropriate cleanup hole, choices of the technician drilling the cleanup hole are somewhat constrained by the available fastener sizes. As will be understood, it makes little sense to create a cleanup hole which is too small for a given stocked fastener, but too large for the next larger sized fastener. The technician instead preferably determines the smallest size cleanup hole which will fully encompass the two misaligned holes  107 ,  112 , but which also has an appropriate diameter for accepting therein one of the available fasteners. Of course, technicians generally stock standard-sized fasteners. For example, technicians often stock standard fastener sizes such as ¼ inch, 5/16 inch, ⅜ inch, 7 mm, 8 mm, 10 mm, 12 mm, etc. Many technicians also stock so-called oversized fasteners which are sized between the standard size fasteners. Thus, for example, between a ¼ inch (0.25 inch) fastener and a 5/16 inch (0.3125 inch) fastener, a manufacturer may stock a first-oversized fastener sized 0.2656 inch and a second-oversized fastener sized 0.2812 inch. 0.25&lt;0.2656&lt;0.2812&lt;0.3125. This gives the technician additional options for cleanup hole sizes. As will be understood, these numbers are merely exemplary. Technicians may stock more or fewer oversized fasteners, or none at all. 
         [0044]    The first through fourth sections  205 - 220  of step gage  200  have diameters  207 ,  212 ,  217 ,  222  with sizes selected to specifically inform the user as to the appropriate cleanup hole diameter. This is accomplished according to the following formula: the virtual hole diameter of the gap is equal to double the diameter of the intended hole (IHD), minus the diameter of the cleanup hole (CUD), which can be written as: VHD=(2×IHD)−CUD. As discussed above, the cleanup hole diameter (CUD) is the diameter of a cleanup hole which would produce concentrically-aligned holes have the same diameter. In the above formula, the intended hole diameter (IHD) can be the actual diameter of an intended fastener (e.g., 0.25 for a ¼ inch diameter fastener) or the least material condition diameter (e.g., 0.254 inches for a ¼ inch diameter fastener). 
         [0045]    As noted above, there is a set of cleanup hole diameters corresponding to the diameters of the available fasteners. This set of cleanup hole diameters is, thus, a set of predetermined hole diameters that are preferred by the technician because holes having these diameters will accept available fasteners therein. One of these predetermined cleanup hole diameters (CUD) can be inserted into the above formula, along with the intended hole diameter (IHD). The resulting number will be equal to the virtual hole diameter (VHD) of the misaligned holes which would have a cleanup hole having the CUD value used in the formula. A step (also referred to as a “section”) of gage  200  may then be created with the determined virtual hole diameter. If that step fits within the gap defined by a misaligned set of holes  107 ,  112 , the technician knows that a cleanup hole having the CUD used in the equation for that step will clean up the misaligned holes. 
         [0046]    The above-discussed non-limiting example of a first standard fastener having a first fastener diameter (e.g., 0.25 inches) will be used to further clarify the use of the above formula. The first standard fastener is associated with a hole having a least material condition diameter (e.g., 0.254 inches). For a situation as shown in  FIG. 1A  in which the holes  107 ,  112  are properly aligned, no cleanup hole is formed because the gap resulting from the overlapping holes  107 ,  112  has a first VHD that is equal to the least material condition diameter associated with the first standard fastener. In other words, the first cleanup hole diameter is already equal to the VHD. The first section  205  of step gage  200  would therefore simply have a diameter  207  of about the VHD. Thus, if the first section  205  of step gage  200  fits within the gap  100 A created by aligned holes  107 ,  112  as shown in  FIG. 3A , then the first standard fastener should fit through the gap  100 A. Another way to confirm this, of course, is simply insert the first standard fastener through the gap  100 A. 
         [0047]    A first oversized fastener has a second fastener diameter that is larger than the first fastener diameter (e.g., a diameter of 0.2616 inches), and a second cleanup hole diameter (e.g., 0.2656 inches) is associated with the first oversized fastener. The formula results in a first virtual hole diameter (e.g., (2×0.254)−0.2656=0.2424 inches). The IHD has not changed from the example above, because the IHD is equal to the originally intended hole diameter of holes  107 ,  112 . Thus, the diameter  212  of the second section  210  of step gage  200  is equal to the first virtual hole diameter (e.g., 0.2424 inches). If the second section  210  of step gage  200  fits into the gap  100 B defined by the misaligned holes  107 ,  112  but the first section  205  does not, as shown in  FIG. 3B , the gage  200  indicates that a cleanup hole having the second cleanup hole diameter will accept the first oversized fastener therein. 
         [0048]    A second oversized fastener has a third fastener diameter larger than the second fastener diameter (e.g., 0.2772 inches), and a third cleanup hole diameter (e.g., 0.2812 inches) is associated with the second oversized fastener. The formula results in a second virtual hole diameter (e.g., (2×0.254)−0.2812=0.2268 inches). Thus, the diameter  217  of the third section  215  of step gage  200  is equal to the second virtual hole diameter (e.g., 0.2268 inches). If the third section  215  of step gage  200  fits into the gap  100 C defined by the misaligned holes  107 ,  112  but the first and second sections  205 ,  210  do not, as shown in  FIG. 3C , the gage  200  indicates that a cleanup hole having the third cleanup hole diameter will accept the second oversized fastener. 
         [0049]    A second standard fastener has a fourth fastener diameter larger than the third fastener diameter (e.g., 0.3125 inches), and a fourth cleanup hole diameter (e.g., 0.3165) inches is associated with the second standard fastener. The formula results in a third virtual hole diameter (e.g., (2×0.254)−0.3125=0.1955 inches). Thus, the diameter  222  of the fourth section  220  of step gage  200  is equal to the third virtual hole diameter (e.g., 0.1955 inches). If the fourth section  220  of step gage  200  fits into the gap  100 D defined by the misaligned holes  105 D,  110 D but the first through third sections  205 - 215  do not, as shown in  FIG. 3D , the gage  200  indicates that a cleanup hole having the fourth cleanup hole diameter will accept the second standard fastener. 
         [0050]    As will be understood, the same formula can be used with various fastener diameters and various cleanup hole diameters (which correspond to various oversized/standard diameter fasteners) to determine the appropriate diameter for a given step on gage  200 . When two oversized fasteners are available with diameters between two standard diameter fasteners, a step gage  200  as shown in  FIGS. 2 and 3A-3D  can be created with four steps: a first step  205  corresponding to the first standard fastener, a second step  210  corresponding to the first oversize fastener, a third step  215  corresponding to the second oversized fastener, and a fourth step  220  corresponding to the second standard fastener.  FIG. 3E  depicts a fastener  300  that secures plates  105 ,  110  together inserted into the cleanup hole. 
         [0051]    It is noted that fewer or more steps could be included in the step gage  200 . For example, when no oversized fasteners are available, a two-step gage having one step corresponding to the first standard fastener and another step corresponding to the second standard fastener. Further, when only a single oversized fastener is available, a three-step gage may be used. Alternatively, regardless of the number of oversized fasteners available, step gages with any desired number of steps can be used. The four-step gage  200  shown in  FIG. 2  and the specific diameters discussed above are therefore merely exemplary, and should be considered a non-limiting example. 
         [0052]    Once the appropriate cleanup hole diameter is determined, a device such as reamer  400  shown in  FIG. 4  may be used to create the cleanup hole. As shown, reamer  400  is a tapered reamer  400 , and includes a shaft  402 . Shaft  402  may include a chuck shaft  405  and a bushing shaft  410 . Tapered reamer  400  also includes a lead portion  412  extending from the shaft  402 . The lead portion  412  includes a final diameter section  415  that has a final diameter  417 . Extending from the final diameter section  415  is a tapered diameter section  420 . The tapered diameter section  420  includes a proximal end  422  abutting the final diameter section  415  and a distal end  424  opposite the proximal end  422 . The proximal end  422  has the final diameter  417 , and the distal end  424  has a beginning diameter  425 . Accordingly, the tapered diameter section  420  decreases in diameter from the final diameter  417  to the beginning diameter  425  from the proximal end  422  toward the distal end  424 . The lead portion  412  preferably includes one or more flutes  427 . Flutes  427  may be straight, helical, or any other suitable configuration. 
         [0053]    Preferably, the tapered diameter section  420  tapers from the final diameter  417  to the beginning diameter  425  at a predetermined angle  430 . The predetermined angle  430  may be between about 0.5 degrees to 1 degree per side (i.e., half-angle), which gives about 1-2 degrees angle overall. When manually positioned at the center of a virtual hole  120 B,  120 C,  120 D the angle  430  of tapered diameter section  420  allows the reamer  400  to remain at approximately the center of the virtual hole  120 B,  120 C,  120 D. This is referred to as positional accuracy. The angle  430  is selected to avoid using a jig to position and hold the reamer appropriately. Further, by centering on the virtual hole  120 B,  120 C,  120 D, a smaller diameter cleanup hole can be created, as compared to centering a reamer on only one of the holes  107 ,  112  (which also generally entails the use of a jig). 
         [0054]    The angle  430  is derived as a balance between competing factors. On one hand, a more gradual taper (e.g., a small value of angle  430 ) would lead to a tapered diameter section  420  having a greater length than a length of section  420  having a larger angle  430 . On the other hand, the angle  430  of the tapered diameter section  420  guides the tapered reamer  400  through the center of the virtual hole  120 B,  120 C,  120 D and gap  100 B,  100 C,  100 D during reaming. A less gradual taper (e.g., a larger value of angle  430 ) may increase error in the positional accuracy of the tapered reamer  400  (i.e., the reamer  400  may stray from the center of the virtual hole  120 B,  120 C,  120 D during reaming). Indeed, it has been found that a larger value of angle  430  results in a tapered reamer  400  which may not remain centered on the center of the virtual hole  120 B,  120 C,  120 D during reaming. Charts illustrated in  FIGS. 5A and 5B  provide exemplary relationships based on the angle of the tapered diameter section  420  that can be used select the angle of taper. 
         [0055]      FIG. 5A  illustrates the relationship between the angle (in degrees) of taper of the tapered diameter section  420  as compared to the length of tapered diameter second  420 , when the each of the objects being secured together (e.g. plates  105 ,  110 ) has a thickness “t” of 0.1 inches. As can be seen, below about 0.5 degrees of taper, the length of the tapered diameter section  420  increases exponentially. Therefore, degrees of taper below about 0.5 degrees may be undesirable in some applications.  FIG. 5B  illustrates the relationship between the angle (in degrees) of taper of the tapered diameter section  420  as compared to the positional accuracy (in inches) of the tapered reamer  400  (in which lower numbers are more accurate). As can be seen, above about 1 degrees of taper, the positional accuracy of the reamer  400  may not have the accuracy specified for a high-accuracy manufacturing process, such as manufacturing machinery. Therefore, an angle of taper below 1 half-degree would be more desirable for the high-accuracy manufacturing process. 
         [0056]      FIG. 6  illustrates a flow chart of a method  600  for using the step gage  200  and tapered reamer  400 , according to an example embodiment. At step  605 , the step gage  200  is inserted into the gap, such as gap  100 A- 100 D defined by at least two overlapping holes, such as holes  107  and  112 . At step  610 , a determination is made as to whether the first section  205  of the gage  200  fits within the gap. If the first section  205  fits through the gap, at step  615 , the first standard fastener may be inserted into the gap. If the first section  205  does not fit through the gap, at step  620 , a determination is made as to whether the second section  210  of the gage  200  fits within the gap. If the second section  210  fits through the gap, at step  625 , the tapered reamer  400  is used to produce a cleanup hole having the second cleanup hole diameter such that the cleanup hole accepts the first oversized fastener having the second fastener diameter. The tapered diameter section  420  is inserted at least partially into the gap, and the misaligned holes are cleaned up to the diameter of the final diameter section  415 , which is approximately equal to the second cleanup hole diameter. At step  630 , the corresponding first oversized fastener can be inserted through the cleanup hole. 
         [0057]    At step  620 , if the second section  210  does not fit through the gap, a determination is made at step  635  as to whether the third section  215  of the gage  200  fits within the gap. If the third section  215  fits through the gap, at step  640 , the tapered reamer  400  is used to produce an initial cleanup hole having the second cleanup hole diameter such that the initial cleanup hole would accept the first oversized fastener. At step  645 , a standard reamer is then used to enlarge the initial cleanup hole to a final cleanup hole having the third cleanup hole diameter to accept the second oversized fastener having the third fastener diameter. A standard reamer may be a reamer without a tapered diameter section, in which the lead portion has a substantially uniform diameter throughout its length. After the tapered reamer  400  has produced an initial cleanup hole at step  640 , a standard reamer may be used with acceptable positional accuracy. More specifically, the tapered reamer  400  produces an initial cleanup hole having a center aligned with a center of the virtual hole that was associated with the resulting gap. Accordingly, the standard reamer may remain centered on the center of the initial cleanup hole formed by the tapered reamer  400 , and the use of a jig to position and hold the standard reamer on the center of the initial cleanup hole can be avoided. At step  650 , the second oversized fastener can be inserted through the final cleanup hole. 
         [0058]    At step  635 , if the third section  215  does not fit though the gap, a determination is made at step  655  as to whether the fourth section  220  of the gage  200  fits within the gap. If the fourth section  220  can be inserted through the gap, at step  660 , a jig and reamer (or other drilling tool, as appropriate) for producing a hole having the fourth cleanup hole diameter for the accepting next standard sized fastener are utilized. The jig and reamer of step  660  may be utilized when the virtual hole has a sufficiently small diameter that the tapered diameter section  420  of tapered reamer  400  may not properly guide the tapered reamer  400  through the center of a virtual hole with. At step  660 , if the virtual hole has a diameter which is large enough to allow use of the tapered reamer  400  without a jig, the fourth cleanup hole may be produced according to steps similar to steps  640  and  645 , with at least one progressively larger reamer used after the tapered reamer  400  has been used. If, at step  655 , the fourth section  220  does not fit within the gap, at step  665  the misaligned holes are flagged for further processing. 
         [0059]    As will be understood, method  600  specifically relates to a four-step gage  200  that can be used when two oversized fasteners and two standard fasteners are available. A modified methodology would apply to a step gage with a different number of sections. For example, when only a single oversized fastener and two standard fasteners are available, a three step gage may be used and method steps  635 - 650  may be omitted. Additional method steps may be added for step gages with additional steps. 
         [0060]    As is evident from the foregoing description, certain aspects of the present implementation are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. It is accordingly intended that the claims cover such modifications and applications that do not depart from the spirit and scope of the present implementation. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense. 
         [0061]    The steps of the methods described herein need not be executed in the order described, or in any particular order. Moreover, various activities described with respect to the methods identified herein can be executed in serial or parallel fashion. In the foregoing Detailed Description, it can be seen that various features are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter may lie in less than all features of a single disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment. 
         [0062]    The various examples shown above illustrate a step gage, a tapered reamer, and a method for using same. A user may choose any of the above embodiments, or an equivalent or variation thereof, depending upon the desired application. In this regard, it is recognized that various forms of the subject step gage and tapered reamer could be utilized without departing from the spirit and scope hereof. 
         [0063]    As is evident from the foregoing description, certain aspects hereof are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. It is accordingly intended that the claims shall cover all such modifications and applications that do not depart from the spirit and scope hereof. 
         [0064]    Other aspects, objects and advantages hereof can be obtained from a study of the drawings, the disclosure and the appended claims.