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Zenith CruZer & Sonex Logs
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Date: 9-6-2008
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Number of Hours: 5.00
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Manual Reference: SNX-W15
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Brief Description: Completed Forward Ribs
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Completed plans page SNX-W15.
Deburred all 8 forward ribs, along with 16 gussets. Took approximately 15 mins per rib/gusset pair. Cleco'd back into position, and riveted with CCP-42 rivets. 11 rivets per gusset, 2 gussets per rib, 8 ribs. 16 * 11 = 176 rivets.
Had to drill-out and replace 4 rivets because the heads were not seated tight against the gusset. On two of them, the rivets spun (used the drill press), and scored the gusset quite deeply. Got frustrated with one of them, and distorted the gusset/rib a bit. Was able to straighten both out such that the flange and rib were straight, but it is not pretty. Added two add'l rivets in the vicinity of the bad rivet hole, but will check with Sonex to see if I should chalk it up to experience and get a new rib/gusset pair.
UPDATE: 9 Sep 2008: Sonex says that there's no loss of structural integrity with what I did; in fact, they said the add'l rivets were unnecessary. So, since tonight was my local EAA chapter meeting, I took the rib to show my tech counselor. Of course, he wasn't there this one night! I showed the rib to a professional (i.e., making $$ at it) A&P. He said it should be just fine; there was just a bit of concern about the closeness of the helper rivets. He said that although it was fine, if I would be thinking about it during flight or at night, just go ahead and replace it now before anything gets put together. New rib / gussets on order. I feel good about the decision.
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8 Completed Forward Ribs/Gusset Assy's
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Bad Rivet lower R; two add'l rivets added.
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