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Zenith CruZer & Sonex Logs
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Date: 9-17-2011
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Number of Hours: 3.00
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Manual Reference: SNX-F01
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Brief Description: Frustrating, Wasted Day
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I set out today to rivet the aft spar tunnel into place in the fuselage.
I decided to start with the flush rivets inside the spar tunnel; figured to get the hard ones done first.
Got several rivets placed; no special order. I noticed that my Arrow-brand manual rivet gun was not doing a good job; was getting hung-up and not releasing the mandrels, or would not complete the pull. I tried disassembling and cleaning the jaws, springs, etc., to no avail. Finally gave up and went to Lowes to get a new rivet gun. That solved that part of the problem, but a few of the places (like the 4th row "in" from the edge, and those at the extreme top, still had some access issues.
After the first rivet that passed through the tunnel skin, the attach angle, and the .090 gusset, it looked like there wasn't enough "grip" on the shop head, so I rechecked the plans. Yup, I was using the as-spec'd CCC-44 rivet. Hmmmm.... guess Sonex knows what they're doing. There *was* a note there to check the detail diagram, which looked like all the other flush rivet detail images I've seen while building. Or so I thought.
After I got all rivets done that went thru the gusset, I re-checked the plans again, and then saw it. The gusset either needs to be countersunk on the aft side to provide more grip for the shop head, or use CCC-46 rivets. Rats. Had to drill out all of the gusset rivets. Of course, I don't have enough CCC-44 rivets even if I countersunk the gusset, and didn't have any CCC-46 rivets, either. So, this is on-hold until I get new rivets. Very disappointing. I *checked* the plans when I suspected something, but just glossed-over the details I *thought* I had seen several times before. I just didn't catch the slight difference.
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