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Traci and Tom's RV-7A
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Date:  7-23-2013
Number of Hours:  1.50
Manual Reference:  
Brief Description:  Rivet removal Horizontal Spar - Part II (Success!)

After going to bed at 1:30 am, after I practiced on the scrap, I slept better about what I had to do the next day.
After asking questions on forums and other builders on the Facebook group, I felt more confident that I could get the rivets out.
I was correct! Practice makes perfect (or at least usable). I had to go in the back side and drill out the shop end of the rivets and it worked better this time. I did learn the following:
- If you are drilling and it goes off center, just angle and aim toward the center. Go vertical again once you get there with the drill.
- Drill deeper! I was afriad of going too deep, but I wasn't going far enough. If centered, your hole won't get destroyed.
- If you are deep enough, the head should just pry out nicely. (Again I stress DEEP ENOUGH - I wasn't there).
- Don't be too scared of giving it a good firm whack with the hammer and punch to get the center out. Just make sure you have good, even support behind. I have a 1 inch nut that I used and it supports it well.

In the photos I show my result. It's not super pretty, but the rivets will fit in fairly snugly and will spread out when squeezed. It should be ok. I deburred a little, then used Scotchbright to polish it down nicely. Acetone cleaned, then a couple coats of prime. Back at it.
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Small edges where I miss drilled (before I knew better)

Small edges where I miss drilled (before I knew better)

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Back side.  Holes seem ok.

Back side. Holes seem ok.

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