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Date:  2-15-2011
Number of Hours:  2.50
Manual Reference:  640-C-5
Brief Description:  Aileron bellcrank spool

The first thing I nopted was that the drilled hole for the shaft is not centered in the spool assembly. Sooo, I had to measure out the distance I needed from the edge of the hole out all around it. I then just selected 4 points at 90 degree angles from one another (or close to it). The supplied rivets were a little too long for joining the pieces so I had to trim them. I undersize drilled the holes to A4s, then after everything was in place I drilled to A5. I cleaned everything up, painted in between the parts and bucked the solid rivets. In the third picture, it can be seen that trimming the rivets gives them the proper head height after bucking.
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rivet hole placement

rivet hole placement

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Trimming the rivets

Trimming the rivets

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Bucking the rivets

Bucking the rivets

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