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Terrences Web Site
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Date: 1-3-2008
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Number of Hours: 3.00
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Manual Reference: 6W1 9
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Brief Description: Reassemble and rivet flaps
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1. Clecoed the right flap together and riveted, 1st the front, then the bottom, then the top.
2. Roger had suggested that I delay attaching the control plate until I actually mount the wings to the fuselage so that I be sure the control plate aligned perfectly with the flap control rod. I decided to take this one step farther and to not rivet in the inboard ribs until the wing are fit to the fuselage. I checked to make sure that the inboard ribs could be easily inserted into the riveted wing.
3. After the bottom was riveted, the trailing edge rivets could not be inserted on the top because the rivet on the bottom is in the way. The pilot holes should have been offset to avoid this problem. I recall there was a place on the empennage where the holes were offset to avoid this sort of problem. ZAC really should modify their pilot drilled kits to eliminate this conflict.
4. Called ZAC; Caleb suggested tilting the top rivet and forcing it in until an edge was in contact with the skin. Then pulling the rivet with a hand riveter and moving it normal to the surface as it shortens. He said that if the rivet could not be inserted until an edge was in contact with the skin, then the hole should be enlarged with a drill at an angle until the rivet could be inserted.
After examining the aileron skins for the same problem and looking again at the flaps, I concluded that the conflict would be reduced if I had riveted the top- trailing-edge-skin before the bottom skin. It looks like, because of the angles and placement of the pilot holes, a set bottom rivet interferes with the top rivet insertion more than vice-versa. I'll check out that on the aileron build. Of course, the problem will be less critical with the ailerons, because they use the smaller A4 rivets.
5. Inserted, drilled, and pulled as instructed by Caleb. One rivet would not insert quite to the surface of the skin. I pulled it anyway, hoping that I could force it down as it shortened. It did not work. The rivet ended up up ~1-mm above the surface. I dr
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Left flap, riveted
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