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Date:  2-11-2019
Number of Hours:  6.00
Manual Reference:  6-ZU-2/1-3
Brief Description:  Disassemble center spar for upgrade

Disassemble center spar for upgrade

I decided to upgrade the center spar before assembling the skins to the wings because I eventually have to mate the center spar to the wings. I believe that it will be easier to work with the spars than it would with the assembled wings.

1. I clamped the center spar to my spar jigs on the work bench, see photo 1.
2. I drilled out the heads of the A5 rivets holding the forward spar to the rear spar.
3. I used a punch to drive the rest of the rivet from the holes. See photo 2
4. I removed the AN4 bolts, spacers, and washers holding the forward and rear spars together.
5. I used my solid rivet removal tool to drill of the manufactured head from the solid rivets on the spar caps to the front web. I did this with the spar cap laying on the work table. I assumed that the rivets on the center spar were 3/16" rivets like the ones in the wing spar. Unfortunately, I discovered that the center spar solid rivets were 5/32", so I had been using too large a drill when removing rivets from the forward web. This led to enlarging the rivet holes in both the web and the spar cap. I believe that the only way forward at this point is to drill all the holes out to accept 3/16" rivets, and to put it back together with 3/16 rivets. See photo 3 which shows spar caps from both the forward section and the rearward caps.
6. After the rivet were drilled I knocked off the rivet heads with a cold chisel and a hammer.
7. Then I clamped the web and spar caps onto the jigs, and used a rivet gun with a 1/8" punch to drive out the rivet shanks.
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Center spar clamped for work

Center spar clamped for work

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After pop rivets removed

After pop rivets removed

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