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Johns Web Site
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Date: 7-15-2015
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Number of Hours: 1.50
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Manual Reference:
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Brief Description: Aft Fuselage Issue Repaired
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Since the bottom aft skin was off, I decided to take care of a minor problem with the aft top skin at turtledeck former #3. Because I did not pay close enough attention to the Builders Manual when installing the turtledeck skin over the formers, I left the center former (#3) slightly lower than the skin, and riveted the former to the bulkhead below it in this position. When the Turtledeck skin was riveted to the formers, it was pulled down locally at four of the rivets. I did not take notice of it immediately, but when I did, I knew I would have to fix it or wish I had for as long as I owned the plane. After the aft lower skin is attached it would be very difficult to fix it, so now was the opportune time.
The only practical and inexpensive way to fix this eyesore was to fill the small gap between the former and the skin, at the rivet locations in its unconstrained condition. To fill the gap, I took some aluminum pop-rivet backing plates that were ½” in diameter, about 0.015” thick, with 1/8” holes through the center. I dimpled them with a standard 120-degree dimple set.
I drilled out the four offending rivets then pushed a thin aluminum wedge between the skin and former, adjacent to the rivet hole, to provide better access at the rivet holes. The space between the skin and former at the two upper holes required three of the dimpled backing plates to completely fill the gap. These were stacked together and pushed into position at the rivet holes, then the aluminum wedge was removed. New rivets were installed and looked very good. The third hole only needed two dimpled backing plates, and the fourth hole needed only one. Two more replacement rivets, and the job was done.
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Dimpled and Unmodified Rivet Backer Plates
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