When I was assembling the "middle" rudder rib to the rudder spar, I accidentally used the wrong rivet length. I used my new rivet removal tool to drill out the rivets, but somehow, the drill ended up missing the original holes--causing the 3 holes in the rudder spar to be "oblong".
A couple of colleagues suggested going to the next bigger rivet size, but I didn't think that the rivets would set properly in the oblong holes. My solution was to fabricate two plates that will reinforce the area and provide three "clean" (i.e. round) holes for the three rivets.
This was a frustrating mistake... I need to practice drilling out rivets with my rivet removal tool.
