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06-20-2010, 07:20 PM
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Join Date: Jan 2009
Location: Hong Kong
Posts: 153
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Countersunk too deep...
Hi all,
Does anyone know what is the tolerance for countersink? I was countersinking on the Z brackets for my tank, I didn't enlarge the hole, but it definitely went deeper than the rivet head. Should I replace the bracket?
Many thanks!
Hank
__________________
Hank Cheng
RV8 Super Slow Build Kit
Titan IOX360, Catto 3 Blades RV prop, Full Dynon everything + Garmin GTN650
First RV in Hong Kong
First Homebuilt aircraft registered in Hong Kong "B-KOO"
Completed RTW journey in 2016
Built with a group of High School Students
Aircraft donated to the Hong Kong Science Museum
In memory of Michael Tam
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06-20-2010, 07:37 PM
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Join Date: Jan 2005
Location: 57AZ - NW Tucson area
Posts: 10,011
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This is the specification --
Quote:
Originally Posted by HighSchoolBuilders
Hi all,
Does anyone know what is the tolerance for countersink? I was countersinking on the Z brackets for my tank, I didn't enlarge the hole, but it definitely went deeper than the rivet head. Should I replace the bracket?
Many thanks!
Hank
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3.3.6 Countersunk rivet head flushness. Unless otherwise specified on the engineering drawing or specification, flushness limits shall be 0.010 inch above to 0.005 inch below the material surface. Countersink diameters are provided in Table IV for reference
The entire document I created is now on Vans web site...
http://www.vansaircraft.com/public/Specs.htm
__________________
Gil Alexander
EAA Technical Counselor, Airframe Mechanic
Half completed RV-10 QB purchased
RV-6A N61GX - finally flying
Grumman Tiger N12GA - flying
La Cholla Airpark (57AZ) Tucson AZ
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06-20-2010, 08:14 PM
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Join Date: Jul 2007
Location: Mesquite, TX
Posts: 936
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Quote:
Originally Posted by HighSchoolBuilders
Hi all,
Does anyone know what is the tolerance for countersink? I was countersinking on the Z brackets for my tank, I didn't enlarge the hole, but it definitely went deeper than the rivet head. Should I replace the bracket?
Many thanks!
Hank
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I wouldn't. The countersunk rivets are not structual... they simply hold the nutplates in place. I'd slap a rivet in there and move on. May even try an "oops" rivet.
Build on. |
06-21-2010, 09:05 AM
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Join Date: Jun 2010
Location: Brisbane Australia
Posts: 166
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Do you have access to a Lathe, you can make up a countersink filler out of some 7075 T6 material to the depth that you CSK by mistake, then CSK the filler to the required depth of the rivets your using, use the filler under the head of the rivet and away you go, the other thing to keep in mind is that you haven't knife edged the material, one rivet might be OK depending on where it is.. If you have alodine 1200 and a decent primer, that will help against the possibility of corrosion later on.
Nick..
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06-21-2010, 09:21 AM
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Join Date: Nov 2006
Location: Waco, Texas
Posts: 1,658
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Might be possible to countersink a bit more and use an AN426-AD5 rivet in there too...
Phil
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06-21-2010, 09:24 AM
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Join Date: Oct 2005
Location: South Hamilton, MA
Posts: 521
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Another approach
I have also seen Van's recommend using JB Weld to fill the hole, then redo the countersink at the correct depth. I was surprised that JB weld is so strong.
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Antony
RV-7A
Empenage complete, wings complete, tip-up canopy complete, starting wiring ...
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06-21-2010, 09:27 AM
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Join Date: Jan 2009
Location: Hong Kong
Posts: 153
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Many thanks! I don't think I can get a -5 in because it's limited to the size of the platenut. I will see if I can get a photo and see what you guys think, thanks!
Hank
__________________
Hank Cheng
RV8 Super Slow Build Kit
Titan IOX360, Catto 3 Blades RV prop, Full Dynon everything + Garmin GTN650
First RV in Hong Kong
First Homebuilt aircraft registered in Hong Kong "B-KOO"
Completed RTW journey in 2016
Built with a group of High School Students
Aircraft donated to the Hong Kong Science Museum
In memory of Michael Tam
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06-21-2010, 10:11 AM
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Join Date: Feb 2007
Location: Mpumalanga, South Africa
Posts: 1,065
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Couple of things you can do. Firstly, if it is only slightly oversunk then it will pull in when you squeeze it. Secondly, if it is deeper but the hole is not enlarged then you can make a drift by inverting another rivet on top and squeezing the 2 together.
Sent you a PM.
__________________
Paul
Mercy Air, White River FAWV
RV-10 ZU-IIZ - "Zeus"
Building Bearhawk Bravo - RV-18 not available 
2019 Donation Made
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06-21-2010, 01:09 PM
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Join Date: Dec 2006
Location: UK
Posts: 368
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Quote:
Originally Posted by paul330
you can make a drift by inverting another rivet on top and squeezing the 2 together.
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I can second that inverted rivet idea. On my QB fuse as it came from the factory, some of the rivets holding the seat ribs to the spar flange were loose due to a slightly over-deep countersink. An extra squeeze with the inverted CS rivet on top easily fixed it.
__________________
Steve Hutt
West Sussex, UK
RV-7 G-HUTY (not flying yet)
( Tip-UP / TMX-IO-360-M1B / Hartzell 7497-2 / 1x LSE PLASMA III / Dual AF4500's / AF-Pilot AP / 695 )
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06-21-2010, 03:24 PM
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Join Date: Jul 2005
Location: Hubbard Oregon
Posts: 9,027
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Quote:
Originally Posted by shuttle
I can second that inverted rivet idea. On my QB fuse as it came from the factory, some of the rivets holding the seat ribs to the spar flange were loose due to a slightly over-deep countersink. An extra squeeze with the inverted CS rivet on top easily fixed it.
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An other way to do this that is easier to control (in my opinion), if you have access to a whitney hole punch. Make a guess at how deeply you over countersunk. Punch a slug in proper thickness material with the hand punch, at a diameter that is close to the diam. of the rivet head. Use the slug as a spacer on top of the recessed rivet head (you can tape it in place if necessary).
Not that I have ever had to do this my self....
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Opinions, information and comments are my own unless stated otherwise. They do not necessarily represent the direction/opinions of my employer.
Scott McDaniels
Van's Aircraft Engineering Prototype Shop Manager
Hubbard, Oregon
RV-6A (aka "Junkyard Special ")
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