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Kurt Haller RV-9A
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Date:  2-25-2007
Number of Hours:  8.00
Manual Reference:  7
Brief Description:  Main spar tank attach nutplates

Started on the 124 K1100-08 nutplates for attaching the tanks to the main spar web. Decided to reuse the angle from the rudder and elevator AEX trailing edge fabrication to provide a solid pilot for the csk bit. (Image 1.) The nutplate holes are not evenly spaced. By noting the inboard/outboared orientation of the angle, I could flip it over to do the opposite flange, as well as re-use it on the other wing main spar.

The #40 csk for the flush rivets really didn't require it, but a csk big enough to accept a dimple in 0.032 Alclad for a #8 screw goes through the 0.063 spar flange. (Image 2.)
The resulting csks look huge (Image 3), but I made a couple test dimples in 0.032 scrap and the fit is good.
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Angle for the big csking

Angle for the big csking

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Csk penetrates spar web into backing angle

Csk penetrates spar web into backing angle

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Resulting csks--very uniform, and very large!

Resulting csks--very uniform, and very large!

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