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Larry Winger's 601XL Project
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Date:  2-7-2010
Number of Hours:  6.00
Manual Reference:  
Brief Description:  Installed left wing root doubler

After re-reading the plans, it became clear that my solid rivet drilling days were not over. There were six additional rivets on the bottom edge of the wing spar to remove to allow the wing root doubler to lay flat against the spar. Once they were removed, I reassessed my situation with replacing solid rivets. With a fair number of holes that I had to enlarge due to hole damage in the first round, plus one additional one today, I decided to take the leap and fill every single hole with a bolt of the next size up. This has two advantages and two disadvantages. The downsides are cost and extra weight. Once I get the parts, I'll be able to see exactly how much of a weight premium I am paying for the privilege. On the plus side, this allows me to carefully re-drill and ream every hole. I feel much better about that. On top of that, bolts are stronger than rivets. Since I'll take the same approach on the other wing, it will certainly speed up my rivet removal process, knowing that I'm not trying to maintain even one hole in its original condition. I then located and backdrilled four holes into the wing root doubler. Once it was temporarily tightened in place, I used a drift pin to mark the center of all holes, including the wing mounting holes. Then it was off to the driill press to carefully step drill up to one size smaller than the final. Once I had the part in place, I reamed all the holes, and it came out perfectly. Ready for the next step of attaching new nose rib angles on top of the wing root doubler.
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Wing root doubler drilled and ready to bolt in

Wing root doubler drilled and ready to bolt in

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Small rivet holes drilled up to 3/16

Small rivet holes drilled up to 3/16" for AN3 bolts

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Everything in the middle drilled up to 1/4

Everything in the middle drilled up to 1/4" for AN4 bolts

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