Posts Tagged ‘rivet’


January 30, 2012

Today I worked mostly in the baggage area. The floors are drilled, deburred, and dimpled. I’ll just need to prime them now. The F-750 side walls were riveted on. The rudder cables will need to be feed through the bulkheads behind this panel so I left some string sitting in the holes to pull the cable through. Finally I carefully countersunk the side rails above the arm rests. Other than cleaning up a few holes, I should be ready for a mass priming session next weekend. Here’s hoping for a warm front on Sunday.





Fuse Rivet Session 3

December 5, 2011


Another Sunday. Another visit from P Dub. In 4 hours we were able to get the sides and a lot of the bottom skin finished today.

The rear edge of the bottom skin turned our really nicely. I am going to follow Chad’s lead and fill all the overlapping gaps with proseal to keep the cockpit weather tight.

The intersection of the side, bottom and aft skins came out really nice. A little proseal to close out some gaps and we’ll be done here. I did have to drill out one rivet on the opposite side. I also used longer rivets than spec’d on a couple of the tab flanges here so a good shop head would form.

The last thing we did before knocking off was to seal and rivet the bottom firewall to the 772 skin. I used 3M Firebarrier 2000+ to guard against CO2 fumes and as protection against an engine fire.

In the Belly of the Beast… Again

November 23, 2011

Don’t be fooled. I haven’t turned over the fuselage just yet. I simply flipped the photo so I could image the fuselage right side up for once. Today I took off from work and concentrated on the interior rivets I have left to complete. There’s the 18 rivets that connect 706 to the aft baggage ribs; 3 rivets connecting 707 to the bellcrank stiffener; 6 rivets for the aft arm rest and finally 4 rivets that attach the 715 ribs to the rear wing spar.

I can’t get all of these by myself. But a number of them are in very close quarters and hard to buck anyway. I am using cherry max 4-2 rivets for these holes and pulling them myself. Above you can see 3 cherry max’s used just to the left of the bellcrank support brace. Also the lower-most hole (upper in the photo)  in each of the baggage rib/706 intersections.

On the opposite side of the bellcrank supports it wasn’t as straight-forward to pull those rivets. The flange of the bellcrank stiffener overlapped the holes for the 706/baggage rib rivets so that you couldn’t get the manufactured head to seat properly. Trying to pull from the other side would be much more awkward and the resulting shop head might not sit well with the overlapping flange. So I took out the dremel and CAREFULLY scalloped out the edge of the overlapping flange so that the rivet heads sat perfectly against 706. It all turned out well in the end. I set 11 cherrymax rivets leaving 16 more to buck when Paul comes over this weekend.

Fuse Rivet Session 1

November 20, 2011

Today we started the final riveting of the main fuselage. Since I was delayed a week, I went ahead and set most of the longeron rivets called out in the Tip-up instructions using the squeezers. When Paul came over on Saturday, we began at the 704 spar and worked back and forward. We also went back and finished out the rivets in the aft fuse we left open to fit the longerons in place. It had been a long time since either of us riveted so we took it slow in the beginning. In the picture above you can see a couple of clecos left in the longeron. I have a couple of mistakes to repair on the right flange tabs of 710 and 711 so I left those cleco’d until I flip the canoe later.

Here’s the 470 rivets for the 704 spar box and the 705 ribs riveted—mostly perfect. There were a couples of dings caused by the bucking bar slipping of the shop head. No biggie considering the wing will cover this whole area anyway. After 4 hours riveting plus an hour lunch we punched out for the day. I didn’t get as far as I hoped but glad just to get the process started.


April 20, 2011

At the risk of offending the neighbors Paul came over last night for an evening of riveting. We made pretty quick work of the rest of the center section skin rivets so I can move on to  assembling the rest of the fuselage.

I ended up dodging the neighbors phone call, but we did manage to piss off my three year old who told mommy to “make the noise stop!” Oh well I hope you can forgive daddy Cam once you get to fly with me!

Back to it!

April 10, 2011

Wow. I can’t believe it’s been almost a month since the last update. I had some work travel and late nights that ate into building time. Today, my friend Ryan came over to help on the center section riveting. This was his introduction to riveting although he’s been flying with me a number of times when I was still renting the Skyhawks and Cherokee. We finished all the seat ribs and the 705 bulkhead. No rivets needed to be drilled out and Ryan did great to avoid leaving any smiles in the skins. We had to leave the baggage rib riveting till next weekend.

I’ve also made contact with a local EAA Tech Counselor to come look over my progress later this month. Looking forward to having some expert eyes on my progress and correct any bad habits.

I’m also including some pics of notching the longeron because they were still on the camera when I downloaded today’s pics. The picture above shows the notch marked and the punch marks for drilling the radius holes.

Here’s the notch after drilling and roughing out the rest of the notch. After filing it was ready to go. The longerons are now in position waiting to receive the rest the of the fuselage pieces for final drilling.

Taking Shape

February 28, 2011

The final assembly of the center section took a few steps forward this weekend. The seat ribs/705/baggage ribs interface is now riveted. The central ribs were very challenging to squeeze. In fact, I have one questionable rivet that might need to be drilled out. The nutplates for the seat ribs were installed as well. The only thing holding me up is etching and priming the 776 skin before riveting it to the skeleton. The weather wasn’t going to cooperate today to do that, so I decided to work on other details in the shop.

Here’s a view down the center two seat ribs looking at the 705 bulkhead. The top rivets on each vertical row (the skeleton is sitting upside down so its the bottom rivets in this photo) were the difficult ones.

This is a detail of the 705 bulkhead with seat ribs and baggage ribs attached.

The center section is wider than the sawhorse plus I wanted a larger, softer surface for the whole fuselage to rest on upside down. In preparation for attaching the center section to the aft fuselage, I made some wood spans for the stock metal sawhorses I’ve been using.

Another detail I need to prep are the slots in the bulkheads that the longerons slip into. I should have done this when I was prepping the bulkheads but I missed it. I just need to run a file over them to open up enough to have the longeron angle slide in without forcing it.

Aft Fuselage Finished!

January 30, 2011

Paul came over on Sunday and we whipped out the final rivets in about three hours. Other than Paul walking into the corner of the center section skin (guess who won that battle), we finished up unscathed.

Here’s a new view from above. The 706 Bulkhead is not riveted until we marry the aft fuse and center sections. Now back to the center section.


Aft Fuse Riveting Part 2

January 12, 2011

Here’s the project progress from the last couple of weeks. I’m including a lot of pics as these are some of the more interesting sections of the fuse to put together. My friend Paul came over for round two of riveting the aft fuse. We got all the rivets at the far aft end done. We had to drill out 3 or 4 along the way. There’s just a few left on the 707 and 708 bulkheads and J-channel. Another couple of hours should do it.

Next up, I’ve started the initial assembly of the center section after prepping all the ribs (did I mention how tedious that is?). It’s quite the Rubik’s cube to get everything in the right spot. The 776 skin and right side baggage space ribs were just not going together. After silently cussing out Van’s CNC machines for a few hours, I discovered I had the 725R and 726R swapped. WHOOPS. Now everything is clecoed together waiting to be drilled, deburred and dimpled.

One thing I overlooked in my excitment to get the aft fuse together was prepping the rudder cable exit. That little hole to the left of the pass through hole above is for the screw mount. It should be drilled for a #8 screw and dimpled BEFORE the skin is assembled with rest of aft parts. Now I need to get clever about how to dimple the hole.

All the ribs except the 2 outside 715 L and R ribs cleco in place. After everything gets put together, I will need to come back and drill out the front of the 715 ribs using the 704 bulkhead as a guide.

This is the outside intersection of the F-715R rib and the F-705 bulkhead. The bottom flange gets drilled out for a bolt.

Here are the 716/715 ribs and the aft part of the F-704 bulkhead. These will be a mixture of -4 sized rivets and bolts. I’ll need to be ginger while drilling this stuff.

Finally here’s a close up of the last couple of bulkheads in the aft fuse after riveting. The seams on the skins are all tight and I am really happy how it all turned out. The only cosmetic issue is a slight smile on one of the rivets that sits under the HS. I actually think its awesome. I see it as a signature that no other kit will have. However, one signature is enough! Onward…

Meet PDub

December 20, 2010

I can finally put an end to the Hellraiser Pinhead comparisons when showing pictures of the aft fuse. I can also get my clecos back to start putting together the center section.

My coworker Paul (aka Pdub) came over for 3 hours to help rivet the aft fuse. We finished up all of the bottom rivets except for the 706 bulkhead which will be removed a couple of more times. We only had to drill out one rivet dinged up when I pulled the bucking bar away too soon. Paul’s a natural with the gun. He has uncles that work for Boeing so I guess it’s in his genes.

We were shocked at how much lighter the assembly was with even just the bottom clecos out. We’ll do a rivet session after the holidays to finish off the two sides. Meanwhile, I’ll prep and prime the center section.