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Date:  5-21-2010
Number of Hours:  2.00
Manual Reference:  None
Brief Description:  Practice 3/16" Solid Riveting

I plan this as my final practice on pounding the 3/16" rivets for the wing spar. This time I used the Avery rivet gages that I bought since my last practice. I used the same practice bar that I'd been using before, with the addition of an 1/8" bar which increases the practice bar thickness to equal the thickness of the spar caps plus web plus extrusion.

In Fig. 1 the Avery rivet length gage suggests that the Zenair supplied AN470-AD-6-14 rivets are too short by ~1/8" . The gage suggests that the AN470AD-6-16 rivets I bought from Spruce are ~1/16" too long. The guidance on solid rivets says that too long is OK, so long as the shop heads do not develop cracks or form off center. I decided to practice with both sizes.

In Fig. 2 The Avery rivet gage shows that the shop head on the -14 rivet is slightly shorter than spec, while Fig. 3 shows that the diameter is smaller than spec. That strongly suggests to me that the -14 rivets are too short for the spar cap-web-spar cap doubler-extruded angle joint. I will plan to use the -16 rivets, and I do not see any need to shorten them.

N.B. A measurement of the -14 shop head (D=6.6mm & h=1.7mm) shows that the shop head does meet Zenair's Construction Standard CS#403, but not the Mil Spec Standard. Zenair's construction standards for AD-6 rivets (6.0<=D<=8.1mm & 1.4<=h<=3.8mm) are more permissive than MIL-R-47196A (D>=6.2mm & 1.9<=h<=2.7mm) where D is the shop head diameter and h is the shop head thickness. The Avery gage measures D=7.1mm and h=2.4mm, which are Zenair's "nominals."
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Zenair supplied AN470-6-14 rivet

Zenair supplied AN470-6-14 rivet

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Shop head on -14 rivet

Shop head on -14 rivet

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Shop head on -14 rivet

Shop head on -14 rivet

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