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Pete's RV-8 Web Site
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Date: 1-21-2010
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Number of Hours: 4.50
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Manual Reference:
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Brief Description: Begin fabrication of starboard fuel tank
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It was a productive day in the shop. The first task to complete was the machine countersinking of the tank skin using the clecoed baffle to provide a guide and stability for the piloted cutter. I test fitted a rivet to check depth and cut these holes slightly deeper than on the port wing to get a better seating of wet rivets.
Next on the task list was to complete the fitting of the T-405 (tank bracket) and the T-410 (reinforcement plate) to the root end rib. This required some filing to get the 2" measurement correct (trailing edge of bracket is to be 2" from the inside surface of the nose rib flange). I also used a Dremel tool with a cutter and small sanding drum to relieve four locations on the edge of the tank bracket. These ground out areas are where the rivet shop heads protrude through the rib flanges. I will use blind rivets for the four most forward rivets in the tank skin (inboard rib only). This approach worked well on the port tank.
After ensuring a good fit of T-405 to the rib, I match drilled the bracket, the rib, and the T-410 plate. I also match drilled the T-410 plate to the outboard end rib.
Next it was on to the tank skin stiffeners. I had already cut and prepared the stiffeners while building the port wing and tank, so match drilling the stiffeners to the skin was accomplished quickly. Position, clamping, and match drilling the fuel filler cap and tank drain fitting was also relatively easy.
I finished the day by sweeping up the shop, draining the compressor tank, and putting away my tools. I have swept up so much aluminum (chips, filings, dust) it's too bad I don't run a foundry operation. You might be surpprised how much sawdust building aircraft fixtures can also generate over time.
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Final Fit of Tank Bracket
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Match Drill Filler Cap
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Match Drill Drain
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