The Most Stupid Thing I've Done

[macrafic]

A while back, there was a thread where people could post their most stupid mistakes. Well, I'm late, but I have a stupid mistake to add, and would like opinions.

I was installing the static ports into the F-773 side skins (SafeAir ports). The 1st one went in nicely. The 2nd one, however, is where I went on autopilot when I shouldn't have. Of course, everything is turned around from the plans, which only show one side. As such, I ended up drilling for a static port near the bottom of the skin instead of the top.

Well, I proceeded to install the port correctly, but am left with a 1/4" hole, surrounded by 4 rivet holes. The first solution that came to mind was to use the 4 rivet holes to install a backing plate. This would take care of 4 of the 5 holes, leaving just the 1/4" hole in the middle. However, with the backing plate in there, I could fill this with the appropriate "bondo" material before painting, or even fill it now.

For those of you with more body experience than I have, does this sound like a reasonable approach?

- Feeling foolish in Minnesota!

[Sam Buchanan]

Originally Posted by macrafic

A while back, there was a thread where people could post their most stupid mistakes. Well, I'm late, but I have a stupid mistake to add, and would like opinions.

I was installing the static ports into the F-773 side skins (SafeAir ports). The 1st one went in nicely. The 2nd one, however, is where I went on autopilot when I shouldn't have. Of course, everything is turned around from the plans, which only show one side. As such, I ended up drilling for a static port near the bottom of the skin instead of the top.

Well, I proceeded to install the port correctly, but am left with a 1/4" hole, surrounded by 4 rivet holes. The first solution that came to mind was to use the 4 rivet holes to install a backing plate. This would take care of 4 of the 5 holes, leaving just the 1/4" hole in the middle. However, with the backing plate in there, I could fill this with the appropriate "bondo" material before painting, or even fill it now.

For those of you with more body experience than I have, does this sound like a reasonable approach?

- Feeling foolish in Minnesota!

Sounds like a plan, Rich. If that is the most stupid thing you've done thus far, you are a better builder than a lot of us!

I usually don't recommend hiding rivets with filler but this is one instance where I think it would be fine and the uh-oh would be known only to you (and your thousands of friends on this forum).

[mannanj]

You could also cut a 1/4in. circle of alluminum and rivet it to the back up plate. That would fill the big hole when you rivet the whole thing on where the 4 existing holes are. It'll look like it belongs there.

[N941WR]

You could always surfact mount them like I did. Click here for pictures.

[Jeff R]

Man, I wish something like that was the stupidist thing I had ever done. And I haven't even got to the static ports yet.

[grantcarruthers]

If you go with the backing plate and fill to conceal the booboo I'd countersink the rivets, rather than dimple, and oversink them a few extra thousandths. That way they will lie deep to the skin surface and have a space left on top to fill over without leaving a high spot on the skin.

Just a thought

[macrafic]

Thanks for the responses people! I have one more question and one comment.

Question: - What kind of filler would work best for a 1/4" hole that is .025" deep? I would like something that will not shrink/crack over time, will adhere extremely well, and can be sanded/painted.

I got a response from Van's on this mistake and they made a comment that I found very interesting, considering the number of posts that exist in this forum on static port location. Their comment was

"Should work. If it's just a matter of putting (the port) in front of the wrong bulkhead, we've found thru experience that either the 707 or 708 bulkhead works."

[az_gila]

Using the smaller head NAS1097 -3 size rivets in a countersink might also give a cleaner look...

I have found that they tend to fill the countersink better and give a smoother finish - perhaps related to the very slight "bulge" they have on the head?

gil A

[joeboisselle]

For a quick no nonsence filler for small spots like that, I usually dab a little "JB quick." Sandable and paintable.