rivet high vs flat margin
 

Does anyone else find that on some rivets the margin between a rivet being too high and being too flat (according to the rivet gauge) is almost nonexistent? For example, I find that on some of the empennage skin-to-rib rivets, when I use my pneumatic squeezer with some number of washers the rivets are just a smidgen too flat (over-squeezed) according to the rivet gauge. But if I take just one washer out of the squeezer, they come out under-set (again according to the rivet gauge). In these cases I err on the side of slightly over-setting the rivet.

Phil-
You will really want to get an adjustable set for your squeezer. It is much quicker and will allow a much more precise setting. Good luck.

I agree with Steve. I worked with the washers for the entire empennage. What a pain! I broke down and spent the $70 or whatever for the adjustable, and never looked back. IT IS WORTH THE DOUGH!!

now it's just a matter of finding the right adjustable set for my squeezer... I'll look at my squeezer documentation when I get home and maybe you guys can recommend a good one for me...

I think they are all pretty much standard. If you have the 214 style squeezer, the ones from Cleveland, Avery, The Yard, etc...work.

Use a thin washer instead of, or along with, a regular washer to get that smidgen!

Mine Came with different washers
 

My squeezer came with a set of washers with different thicknesses.

I spent about 25 rivets worth of time changing them to get the right stackup and then had enough and called Avery for an adjustable set holder. Never looked back.

Call Avery and tell them what you have and they will hook you up with the right adjustable set holder for your unit.

Use a combination of thick and thin steel washers as required.

Or use the correct parts....
 

Or you could use the correct shims made for the job..... :)

http://www.usatco.com/squeezer_sets_25.asp

They come as thin as 1/64 thick (half of a thin AN washer), and note that they have a bevelled edge on one side. This helps the shim sit correctly since the "pin" to rivet set body is not a sharp corner.... it is radiused for strength.

gil in Tucson

Oversmashing is better than under-smashing
 

In the end, I wouldn't drill out those rivets just because they are a tad oversmashed. Now if they are WAY oversmashed, then I'd consider replacement. If you have to err on one side or the other, err on the side of over-smashing.