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Date:  1-3-2010
Number of Hours:  4.50
Manual Reference:  
Brief Description:  Main Fuel Tank Access Panel

I screwed up the right main fuel tank access panel by drilling the drain plug fitting hole before the fuel tank position was completely settled. I decided to make a new panel rather that elongate the hole. I had to custom order the aluminum from AC Spruce in order to get the right size. I trimmed the aluminum to match the Avipro panel, clamped the new panel to the old one, and match drilled the holes. I drilled out the rivets on the stiffeners, and match drilled the corner holes of the stiffeners on the old panel, and drilled out new holes for the stiffeners. After deburring and dimpling, I primed the interior of the stiffeners as they were somewhat deficient and alodined the panel on both sides after removing the plastic film in the appropriate areas after using a soldering iron and straight-edge to mark out the desired removal coating. Although Avipro used conventional riveting technique in making their panels, I used back-riveting which resulted in very smooth rivet lines. It is key to push the sheet and stiffener together down onto the back riveting plate in order to get flush rivets, I discovered.
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Back riveting the stiffeners.

Back riveting the stiffeners.

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Stiffeners riveted in place and primed.

Stiffeners riveted in place and primed.

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Flush rivets.

Flush rivets.

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