Poor Riveting

[vic syracuse]

In the last week I have performed pre-purchase inspections on a couple of aircraft that had really poor riveting, and I thought I should share them with the group here, as I know there are lots of new builders.

The first one was an RV-10 kit that was supposedly pretty complete, including an Eggenfeller engine. Sad to say, the whole aircraft had some of the worst riveting I have ever seen anywhere. I feel bad for the builder, but the buyer certainly dodged a bullet. The aircraft is really more of a restoration project now rather than a kit needing completion. Here's a couple of photos out of the dozens I took. There was every example of a bad rivet I could think of---underdriven, overdriven, misdrilled, crooked, and cracked. With so much help available today between EAA Technical Counselors and the Internet it is intersting to me that someone would just keep pounding away without seeking advice. It's a lot of lost time and lost money. I remember taking the first pieces I riveted to the flight school A&P at which I was flight instructing. He laughed as soon as I walked in the door! I had to drill them all out and he showed me how to properly set them. The rest is history, but the message is we ALL had to learn. Here are some pictures from the RV10:






The second airplane was an RV-7A that has been flying since 2007. It has had multiple inspections by the builder and an A&P. I was again surprised by the extremely poor quality riveting in a very critical area--- the aileron attach bracket. From Van's service letter we know this is an area prone to cracking with even a PROPER riveting job. This particular area is so easy to get right during the build process. It will require precision now to prevent enlargening the holes on the spar. The first photo is of the right wing. The second photo is of the left wing. Note the poor riveting along the lower rear spar on the right wing, and the rivets are reversed on the aileron bracket. That will make doing the SB even harder. The riveting along the lower aft spar is horrible as well.
And take note of the loose jam nut on the elevator. There was a loose one on BOTH the left and right elevator, and it was clear they had never been tightened, as there was paint on the threads below the jaunt. You would think they would be caught on a preflight, let alone the past 7 CI's. What really irritates me is that the SB for the aileron brackets was published 3 months prior to the last Condition Inspection.

I hate to point this out, but paperwork signoffs aren't doing anyone any favors.

[Electrogunner]

That is definitely disturbing. Buyers beware. Those are some very critical areas to be sloppy. I just performed the SB on my -10 aileron bracket. No excuse for work like that.

[DanH]

Aww, come on Vic....those are just experiments.

[Toobuilder]

The loose jam nut is equally disturbing. I think some people fail to appreciate that with the jam nut loose, ALL loads are going through the 2 rivets on the platenut ears.

Here is an example of a "repair" on my Rocket found after I got the thing home:

[TroyBranch]

WOW, to say the least. I am trying to figure out how someone could think this is even close to OK. Why would they keep going? The dumped rivets wrecked the aft spar. Even without instruction there is plenty of pictures on the net to let everyone know if you are close to what the rivets should look like. I guess there could be people building with no internet access.

Looks like getting back to a mandatory pre cover inspection might be quite helpful. It would be a lot less work to fix at that stage.......but still a ton of work.

I think it is really important to post these kind of things. There is many builders really trying their best on the build. When it is not perfect they beat their selves up. Every one should strive for excellence but know what it is safe if they cant quite get it perfect. When you don't know, always ask before proceeding.

I would be scared to put tools in the riveted tool box kit if it was riveted like this.LOL

[DanH]

Kidding aside, most builders worry about quality, and do a fine job because of it. I doubt there is much anyone can do about the sort of personality who accepts the pictured work as OK. And let's not forget, it's not just a builder or A&P inspection issue. A DAR or FSDO person looked at those airplanes at some point.

Here in Montgomery, a TC has it good. Most of my RV builders have been USAF officers rotating through Maxwell as staff or student. As a group, they're intelligent, well motivated types, for whom details really matter. Attitude counts.

[Andy who?]

This makes me feel much better about the quality of my work.

Of course now if someone offers me a ride I'm going to feel the urge to see their rivet quality first.


Hopefully Vic can inspect my finished product.....just a few more years.

[Bavafa]

Is the plane in the second set of pix of a RV7 or RV12? Considering how many pop rivets it has, this could be a RV12
sad it is but glad it is getting noticed and brought to the attention.

[60av8tor]

The second pic really boggles my mind (I guess they all do). Not to mention your HS is attached to those bars, but those bars are attached before installing the bulkhead into the tailcone - can be squeezed or shot with ease.

Is it the pic or is there something going on with the attaching face of that stringer? Looks almost like a backing piece of aluminum...?

[airguy]

How did the builder get the fuel tanks to seal??