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Jims RV-8
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Date:  6-11-2017
Number of Hours:  2.30
Manual Reference:  8-71
Brief Description:  Baggage Door – continued, Part 3

Today, Bob and I discussed what we think happened and we remembered that when we installed the clecos on the top and bottom holes (because of access issues, you can’t have clecos in those holes when you are blind riveting the fore and aft rows when the door is strapped in place) the holes were off quite a bit and we pulled them in place with the clecos. This is where we feel like things went awry. So with the clecos out, we set the door in place and pressed it back into the proper flush fit. Then we gently lifted it off the fuselage and looked at the holes and – as expected, were slightly off/misaligned. Working with the bottom set of holes first, we re-drilled the misaligned holes to be “aligned” and then we riveted and checked the fit after pulling each rivet. The flush fit held with the addition of each new rivet until all 7 rivets were pulled and the bottom set was done!

Now we just had to do the top and it was looking even better (less misaligned) than the bottom set. I pulled the middle top rivet and checked the flush fit and what do you know – its twisted again…not fitting flush. After just one rivet in the top middle. Drilled that sucker right out and refit the door back on the fuselage to see what was misaligned…couldn’t really see anything misaligned… Tried a different hole with another rivet and the same thing happened – a twist was induced. Bob put on the power glasses and with the dremel and a drill bit hollowed out one hole – seemingly making the new alignment good. But the same thing happened, the door twisted. We even decided that we would drill a completely new hole in the top row, so after pressing the door into place with a good fit and then gently pulling it off the fuse, we drilled a new hole and riveted that one hole. Twisted! Drilled out that hole and decided that pro-seal will hold the top inner skin to the angle and the rest of the outer skin. So, we mixed up a batch of pro-seal, taped off the parts we didn’t want pro-sealed and slathered pro-seal between the skins and
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strapped down again - pro-seal drying

strapped down again - pro-seal drying

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