In between some yardwork, watching the sprinklers, and cleaning up the house, I made some good progress on the airplane.
First thing, I found a stiffener rivet that was sitting a little proud. (Drilled rivet #1 today.)
Silly me, though, I didn’t get any pictures of it after it was reset. I was being lazy with the camera today. Sorry.
Next up, skin deburring and dimpling.
After deburring, scuffing and dimpling, we are ready for priming.
Then, more deburring, scuffing and dimpling.
After cleaning, I shot a little primer on the skin.
I had a very specific order here. First, deburr, scuff, dimple and prime the top, forward edge, and bottom edge. Then, while the primer is drying, devinyl the aft edge (vinyl used as masking for the primer), deburr, scuff and dimple the aft edge. This edge doesn’t get primed, as we’ll use the fuel tank sealing instructions with Pro-seal to glue the trailing edges together.
After scuffing the aft edge, I started pulling off the blue vinyl from the interior of the skins.
Then, I spent a couple minutes making the slot at the bottom of the skin a little bigger. One of the flanges from the control horn fits in here, and during initial assembly, there was some interference.
And the left skin, primed.
Ame thing on this skin, while the primer was drying, I devinyled the trailing edge, scuffed, and dimpled.
Here’s the left skin after devinyling. I’ll store this skin until final riveting. Now, back to the skeleton.
In the middle of the day, I ran out of primer and scotchbrite pads, so I ran out for both.
They didn’t have any maroon on the shelf, but they had some grey. I asked the guy out front, and he went to the back and grabbed 3 unpackaged pieces. Usually, there are $5 or $6 for the three. He gave them to me for a couple dollars, which was nice.
I had some trouble with dimpling the last three holes in the rudder bottom rib. I drilled and countersunk a hole in a spare piece of steel I had, then realized it was too far from the edge to work. Awesome. Here’s a shot of my second attempt.
Then, I moved on to some riveting.
While I was moving everything around getting it ready for riveting, I broke my first tool. Now, it was about $0.50 from Harbor Freight, but I was still upset.
Rivets were looking good, until the one to the right of the nutplate. Doh!
After a successful drill out (#2 of the day), I finished setting the rest of the spar reinforcements and snapped these two pictures.
That’s 16 set so far.
Then I mocked up the R-405PD Rudder Horn, R-710 Horn Brace, R-917 Shim, R-902 Spar, and R-904 Bottom Rib. Some people need to use blind rivets in some of these holes, but I figured I could do it with all solid rivets.
I figured out that if I take off the R-904 bottom rib, I can reach in from above (bottom right of the picture) and get the horn brace to rudder horn rivets here, then slide the forward flange of the bottom rib under the rudder horn and get those from the lightening hole. Here I am setting the horn brace to rudder horn rivets.
Here’s all four of those set (set nicely, if I may add).
20 rivets set so far. Then I moved on to the R-606PP Reinforcement plate to R-902 Spar to R-917 Shim to R-405PD Rudder horn rivets. These need to be AN470AD4-7 rivets, which are LONG. I did have to drill one of them out. That’s #3 for the day. Boo.
But, I managed to reset it okay and get the others in with no trouble.
23 set. I scratched the R-405PD horn a little, so I scotchbrited it out, and shot some primer in there.
Next, I slid the flange of the bottom rib under the rudder horn and lined up the holes. Now I need to drop some rivets in here.
First, I set the horn brace to bottom rib rivets.
26 set. Finally, I set three more which are reinforcement plate to spar rivets.
I started to rivet the complicated stuff together and LOOK WHAT I DID!
This happened because I was bucking from above and shooting from below. The gun jumped around cause I was supporting it’s weight instead of letting gravity help me. That’s a no-no.
It was pretty easy to drill out (#4 for the day), here’s an inside shot; back to square one.
After setting the first two, a picture.
And after much consternation (including using my double offset set as a bucking bar), I got the two outside rivets bucked.
30 rivets set, 4 drilled out. Lastly, I matchrdrilled the E-614-020 to R-912 rib. This was a piece of pie.
4.5 hours today. Not bad for a Saturday afternoon.