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Date:  6-6-2018
Number of Hours:  3.00
Manual Reference:  
Brief Description:  Fix rear spar doubler orientation

I hate fixing avoidable mistakes. I marked the HS-906 doubler "up" direction wrong and now I get to pay for that error. There are 34 AN470 rivets I had to drill out to remove the doubler from the spar. My rivet removal tool paid for itself tonight. I drilled out all 34 heads and popped them off in five minutes. Getting the shanks out was a bit tougher.

I used a #33 bit to drill down about 3/4 into the shanks. The smaller drill bit gave me a little margin away from the hole bearing surface. The rivet removal tool does a good job of centering the drill bit on the head, but it's not exact. I put a rivet caddy under the tail and started pounding. It took about an hour to remove all of the rivet shanks because I was being very careful to avoid damaging the spar and doubler. An examination of the holes showed very little markings from the removal process.

I triple checked the orientation of the doubler and got it riveted back together without further drama. I also riveted the HS-912 hinge brackets to the spar.

The last item was dealing with the unnecessary countersink on the doubler. I used a shorter rivet than called for in the instructions and double-flush riveted the two locations with the shop head resting in its intended location. In retrospect, I should've used an even shorter rivet. I couldn't get the tail flush with the surface, but at least it didn't clench. I thought about drilling it out, but the risk of screwing it up and having to buy new parts wasn't worth it. Structurally, it's sound.
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Yeah, too much primer.  Looks ugly but it's OK. Heads drilled and ready to pop off.

Yeah, too much primer. Looks ugly but it's OK. Heads drilled and ready to pop off.

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Punching out rivets through the thick (0.183 in) stack up was difficult.

Punching out rivets through the thick (0.183 in) stack up was difficult.

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Sorta kinda double flush riveted.  It's not pretty, but it's structurally acceptable.

Sorta kinda double flush riveted. It's not pretty, but it's structurally acceptable.

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