I'm currently working on my wing kit. Its an old 97 kit with only the skins being pre-punched. I installed the nutplates on the top flange of the spar per the plans before starting on the skeleton. When I drilled the tank skin to the ribs and baffle I used two straps to cinch the skin down tight to the ribs. I did not drill the #30 size screw holes on the top side out yet as I used #30 clecos through those into the nutplates to hold the skin on the top side. When I cinched it down, the bottom edge overlapped the bottom main skin by 1/16" to get it touching the ribs all the way around. Before anyone suggests it, no it was not over-tight as I could easily pull the straps away from the skin on the bottom side and for most rivet holes had to actually press the skin to the rib by hand. When I disassembled, the foremost edge of rivet rivet holes into the baffle on the top side are within 1/32 of the start of the radius. (Top of baffle to center of hole is actually .25) By my calcs, I think I would be within military specs to place a 3/32 rivet there but I cannot get even the avery close quarters female dimple die in there to dimple the baffle. If I countersink, I know the hole will wind up out of round. On the bottom side, the holes are 5/16 from top of baffle and can easily be dimpled. The bottom also overlaps the main skin by 1/16 which is more than double what the manual says is allowed.
Anyone have any ideas how this happens and how I can avoid it when I replace the parts and redo? Should I redo? Ken at Van's says I shouldn't have to replace the parts but I don't know that I like the idea of making do with it.
Thanks,
Shadrach
Anyone have any ideas how this happens and how I can avoid it when I replace the parts and redo? Should I redo? Ken at Van's says I shouldn't have to replace the parts but I don't know that I like the idea of making do with it.
Thanks,
Shadrach