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12-18-2017, 05:34 PM
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Join Date: Dec 2012
Location: West Linn,Or
Posts: 88
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Countersunk too deep...
My question is replace the spar (HS 00903-1), or move on...? What surprised me was how fast the single flute countersinking cutter grabbed the material and took off!
https://photos.app.goo.gl/aKu9Nmvpmqo9D3Xr2 |
12-18-2017, 05:51 PM
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Join Date: Mar 2017
Location: Birmingham, Alabama
Posts: 1,635
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Are you using a stop? There is a LOT of counter sinking, totally worth the $$
http://www.cleavelandtool.com/Thread.../#.WjhiuEtMGJY
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RV-14A #140376
N196 (Flying)
2019 Bronze Lindy
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12-18-2017, 05:54 PM
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Join Date: Feb 2005
Location: Abilene, TX
Posts: 724
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Hey Brian
I don't know how thick the material is, but it may have a bearing on if it's too deep or not. I would certainly run it by Vans & see what they have to say.
Also, be sure to make a couple of test runs on some scrap with the countersink cage before you do the part. It may save you some grief.
Good luck
Sam
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Sam Evans
RV7-A O-360 C/S
VAF#812
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12-18-2017, 06:06 PM
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Join Date: Dec 2012
Location: West Linn,Or
Posts: 88
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yes, I was using a cage but obviously screwed something up.... I have an email into VANS. I cant quite tell from reading ahead why the instructions call for countersinking here (page 8-2, step 5), but hopefully it wasn't a $75 mistake! Thanks for the replies.
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12-18-2017, 06:15 PM
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Join Date: Oct 2005
Location: Estes Park, CO
Posts: 3,931
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Countersink
Definately too deep for a rivet but often deep is relative to the part nesting in the countersink and location. Refer to Vans Mil-spec document for countersink dimensions and hopefully they will have good news for you tomorrow.
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Larry Larson
Estes Park, CO
http://wirejockrv7a.blogspot.com
wirejock at yahoo dot com
Donated 12/03/2019, plus a little extra.
RV-7A #73391, N511RV reserved (2,000+ hours)
HS SB, empennage, tanks, wings, fuse, working finishing kit
Disclaimer
I cannot be, nor will I be, held responsible if you try to do the same things I do and it does not work and/or causes you loss, injury, or even death in the process.
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12-18-2017, 06:38 PM
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Join Date: Dec 2010
Location: Colorado
Posts: 226
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Buy a new part and get a fresh start. Use the spar for test holes from now on before you start countersinking other critical areas. I always did a test on a spare piece to make sure the size and depth was correct before proceeding. Countersinking and dimpling are a fundamental skill in assembling an aluminum airframe and you'll have piece of mind when done correctly.
Cheers, Hans
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Build 'em light, keep it simple
I'd rather fly than tinker.
"There's a big difference between a pilot and an aviator. One is a technician, the other is an artist in love with flight."
- Elrey B. Jeppesen,
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12-18-2017, 08:08 PM
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Join Date: Jul 2011
Location: Cypress, TX
Posts: 409
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Quote:
Originally Posted by Eztroller
hopefully it wasn't a $75 mistake! Thanks for the replies.
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Front and rear HS spars are $46 each. Shipping for one or both is $130 to Texas  hopefully you can just go pick up.
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RV14A #140083
Flying! 8/12/19
2019 Donation
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12-18-2017, 08:40 PM
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Join Date: Dec 2012
Location: West Linn,Or
Posts: 88
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Thanks for all of the feedback. I checked the mil-spec and it is definately too big.
Tom,
Thankfully its a 20 minute drive to Vans. Will wait to hear fron Vans, but expecting an early afternoon trip tomorrow.
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12-18-2017, 09:44 PM
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Join Date: Jul 2017
Location: San Jose, CA
Posts: 278
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Quote:
Originally Posted by Eztroller
Thanks for all of the feedback. I checked the mil-spec and it is definately too big.
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You may be able to go to next size up rivet. Check with mothership.
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Dan V
'91 Zodiac flying since 2013
RV-14A in progress
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12-19-2017, 07:40 AM
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Join Date: Sep 2010
Location: Northern NJ
Posts: 82
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Definitely too deep
I made the same mistake on my flap spars. After I made the mistake I found Section 5.5 where Van's recommends 7 'clicks' past flush when countersinking to accept a skin dimple. That corresponds to .007 past flush which is barely perceptible and a lot less than you think you need but it works.
I used my caliper to measure a test piece to set my csink cage then csunk the flap spars. Until I got comfortable I think I measured everyone. Then I measured every 5th one or so. 
Proper depth
Picture of one too deep
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RV-8 empennage DONE
Wings 99% done
Fuselage in progress
Last edited by NavyS3BNFO : 12-20-2017 at 07:00 AM.
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