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Sonnys CH650
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Date:  8-13-2011
Number of Hours:  2.00
Manual Reference:  6T1C Pg 7
Brief Description:  Riveted Spar Doublers

Was planning to completely rivet the stabilizer skeleton but ran into a couple of small obstacles causing me to "hold short at runway nein":

1) After clecoing the components together and inserting a few rivets in the rear spar top doubler I quickly realized that the 23mm diameter barrel of the pneumatic puller would interfere with the upper spar flange; likely causing the forming head to sit at a slight angle to the web. Since the barrel of the hand riveter is only 19mm I decided moving the centerline of the riveter 2mm closer to flange (smaller radius), slow pulling of mandrel and locally bending the flange with the barrel to get a flush seat would be my best bet for forming the rivet heads flush. This took much longer but the results justify the effort.

2) After riveting the four spar doublers I had to prime the front spar web where the Front Attachments are riveted and the doublers where the ribs attach. Final riveting of skeleton will be completed after the primer has thoroughly dried.

Note: It's not obvious from the picuture but all of the mating surfaces between the rear spar, doubler, shim and attachment were masked and primed prior to assembly. I'm leaving the exposed surfaces bare for either polishing or priming/painting with suitable exterior product.

Tip: Cleco the rib holes and front attachment holes to ensure they don't accidentally get riveted.
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Spar Doublers & Rear Attachment Riveted

Spar Doublers & Rear Attachment Riveted

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Hand Riveting Upper Doubler

Hand Riveting Upper Doubler

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Rivet Pullers

Rivet Pullers

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