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Zenith CruZer & Sonex Logs
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Date: 5-30-2008
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Number of Hours: 3.20
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Manual Reference: SNX-T06
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Brief Description: Completed Elevator Horn
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Completed elevator horn assembly today. Up-drilled all rivet holes to #30. Counter-sunk holes in horn for the nut-plate retention rivets (smaller 3/32" rivets) and the 2 CCP-42 rivets above the nutplate to provide room for the trim tab cable that will be mounted to the nutplate after the empennage is mounted to the fuselage. Took it all apart; deburred all, and touched up the black paint on the elevator horn as per plans.
Riveting provided some challenges. Overall had to drill out 3 regular and one flush CCC-42 rivet because they failed the fingernail test. Last week, I bought a cheap Harbor Freight manual riveter to get into the tight spots, like between the angles of the elevator horn. This riveter ($5.99) is junk. Basically, after each pulled rivet, I have to disassemble it because the stem gets caught in the jaws and won't release. The 2nd challenge is that for some reason, it will not "pop" the rivet on one pull. When I tried to do a 2nd pull on it, the stem (being locked in the jaws) would not slide further down into the jaws. Tried 1-2 rivets where I put some needlenose pliers around the stem, which allowed the rivet to pop. But, enough force is exerted that you can see lines on the rivet head where the jaws of the pliers were.
Tried using washers. Didn't have ones with small enough holes, so the rivets tried to pull thru the washer hole. Finally took some scrap and made up an angled block as per the EAA Homebuilder Hints video series. This is a small piece of scrap alumninum thru which you drill a small hole for the rivet stem. You file downt the block so it has a slope on it. You then slightly bend the rivet stem, put this block over the stem, then slide the rivet gun over the stem. This way, I was able to use the pneumatic riveter for ALL of the horn rivets.
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Left Horn w/Flush Rivets
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Backside of Left Horn Showing Nutplate
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Overall View of Completed Horn Assembly
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