Finished Flap Brace, Inspection Ports

November 13, 2012

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Well, with a few short minutes available to me in the garage tonight, I tied up a couple loose-end rivets and started on a new little mini project.

First, I pulled off the right flap and set these nine rivets with my economy squeezer. No big deal.

Hooray, now the flap brace and flap hinge is completely riveted.

Another angle, showing a completely cleco-free inboard wing.

Then, with about 15 minutes left, I pulled out the inspection covers.

I forget the part number, but there are six of them. Three for each wing.

Up to the drawing to see what hardware is needed.

Looks like #8 hardware.

Go searching through my hardware containers…

There they are.

Uh oh. There’s another set of hardware there on the left for the forward side of the inspection covers.

Oh no!

Oh yes.

I drilled the first forward edge to #19 drill size, then dimpled for a #8 screw.

After trying to fit a #8 screw into a #6 nutplate, I realized my mistake, and drilled them correctly on the other 2 (I’m only working 3 at a time.)

Foreground is correct (#6 screws), background is WRONG (#8 screws).

It’s a sad day when I have to make a deposit into the scrap bin. (sigh)

But, I kept at it, and borrowed one of the left wing’s covers (they aren’t handed, just one of the ones that were allocated for the left wing.)

I got them screwed into the forward (bottom in this picture) edge, and started matchdrilling the center holes.

They’ll look good when they’re done.

0.5 hour, 9 rivets.

Time to go run!

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Trailing Edge Angle Work

March 27, 2010

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I didn’t get in a lot of work today, but an hour on the trailing edge isn’t too shabby.

First thing, unpack the Lowes bounty. I picked up a 6′ piece of aluminum angle (for the trailing edge work) a long (36″) backriveting plate, a 36″ 3/4″ diameter steel stake for leading edge rolling, and a smaller backriveting plate that I will be returning (picked that one up before finding the longer one).

Lowes bounty.

I grabbed the aluminum angle, and drilled both sides to the dirtier side of my MDF toolbench.

The cleco on either end will help it stay put.

Then I used the  trailing edge (pre countersunk) to drill the trailing edge hole pattern in the aluminum angle.

I lined up the trailing edge with the aft edge of the angle so I could ensure things were straight both left and right and forward and aft.

Here’s the angle after being Matchdrilled.

Let's do it.

Next up, countersinking the trailing edge wedge to accept the dimple of the skins. I grabbed a piece of stiffener (.016″) and used my standard dimple dies as a test piece. First, I measured the very outside diameter of the dimple.


Then, I conservatively deepened a countersunk hole in the trailing edge until it reached 0.2165″

Here's .187.

A little deeper...there we go.

After finishing both sides with this depth, I clecoed the skin together. Hmm, This doesn’t look that good.

There's a pretty big gap in some places.

I was frustrated this didn’t work out perfectly and I had some socializing to do, so I walked away. I’ll come back to this tomorrow.

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LH skin dimpling, some HS riveting

January 9, 2010

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This morning, I snuck out into the garage and starting dimpling the left hand HS skin with my new (borrowed) c-frame.

After thinking about the setup and trying a few things, I quickly realized I wanted the female dimple die underneath and the male dimple die on top.

I set up the skin on 3 2x4s (I haven’t built a dimpling table yet because I wanted to see how I liked doing it) which was less than a 1/4″ above the female dimple die. Then I basically moved the c-frame around until the male dimple die was lined up (this way I don’t scratch the skin with a male dimple die while trying to locate the hole from underneath, like some builders do). Then I held the male dimple die down into the hole and…WHACK! Perfect dimple. I am far happier with these dimples than the pop-rivet dies. Keep in mind here, I am dimpling with the standard spring-back dies here, not the tank (deeper) dies.

Here's my setup for now. I like this because you move the c-frame, not the skin.

After finishing each row, I put a line of blue painters tape on the outside of the skin. I learned on the practice kit to protect whatever I didn’t want to scratch. The tape will come off just before riveting.

Blue tape on the outside of the skins. Hooray protection!

After I finished both sides, I scuffed up the internal lines, cleaned, then primed the inside of the left HS skin.

Here's the inside of the left skin, all suffed up, ready to prime.

While I waited for skins to dry, I riveted together HS-705, HS-702, and HS-704, but only the middle two holes. The rivets didn’t bend over, per se, but set a little crooked. (My fault for not keeping the squeezer steady.) I drilled them out perfectly, and then decided shooting them might be a better idea. After practicing with a piece of scrap for a minute, I actually ended up shooting these rivets. They look really good.

Shop head picture. Rivets 7 and 8.

Machined head picture. This just looks good.

This is not the order the directions has you rivet, but I was getting antsy to get some primed pieces together. Notice I didn’t slide in the HS-710 and HS-714 yet (still need to finish those), as you can set HS-404 to HS-702 to HS-405 without them. Then, it is off to run some errands.

When we got home from running some errands, my latest Avery tool order had arrived. Finally, a scotchbrite wheel! 6″x1″x1/2″ CP-7AM “Cut and Polish” Medium wheel. Also, I’ve heard some good things about the Permagrit line of products, so I picked myself up one of the 12″(?) ones. Fine on one side, coarse on the other, flat (I heard not to get the curved (convex) one.. Much better for making a straight edge than my regular file.

More tools!

First thing after mounting the scotchbrite wheel, I finished the edges of HS-710 and HS-714 with the wheel. So easy. I should have ordered the wheel at the beginning. (Serves me right for trying to piece together a toolkit instead of buy one all at once. I thought the scotchbrite wheel was a luxury. It is not.) Then I countersunk the holes in HS-710 and HS-714. I had done this before, but sized the countersinks perfectly for a AN426AD4- rivet. When you cleco the dimpled HS-702 front spar to either piece, the spar doesn’t sit flush, so you have to enlarge the countersinks.)

Enlarge countersinks. Check.

Then I finished surface prep, cleaned, and primed those two.

While waiting for the primer to dry, I clecoed HS-707 (leading edge “middle” rib) and HS-706 (tip rib) to the left skin to get in the mood for riveting. The girlfriend and puppies are taking a nap, so I’ll have to come back to this later, but I’m getting excited to start skin riveting.

HS-707 and HS-706 all clecoed to the left skin and such.

Anyway, I put in a few minutes of right HS skin deburring, scuffing, and dimpling before coming in for the day. (Notice I decided to scuff the interior of the right skin before dimpling? It’s easier to scuff the skin without all of the dimples getting in the way. It’s these little things that will save me time the second time around.)

Let’s see. 9am to 11am, 2pm to 4pm. 4 hours today.

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