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Date:  7-27-2013
Number of Hours:  8.00
Manual Reference:  
Brief Description:  Back to work!

Spent another 2 hours organizing and storing the parts; I don't think I'll see the fiberglass tips for quite a whiel.

Back to work ... started in on drilling the spar for the tank and inspection cover nutplates. The immediate questions was how deep to drill the countersinks for the skin dimple? I fabricated a #8 dimple on a 32 mil piece of scrap as a gauge and tested the countersink on size on a piece of scrap. Final diameter that worked well was 0.365" at the surface.

Van's wants you to use undersized pilot in the hole to drill the countersinks .. this would likely come out ugly and inconsistent. I found RudyGreyling's suggestion to back up the work piece with a piece of angle, drill to size both, and then countersink; worked great!. The baking piece holds the pilot nicely and makke for some very nice countersinks (see Tip: Drilling Spar for Tank Platenuts - VAF Forums)

Touched up the bare metal with alodine and rivet using my favorite alligator squeezer. Came out great! Finished up to riviting one side; 3 more to go.
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Humm baby, ain't they pretty

Humm baby, ain't they pretty

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Countersinks in progress

Countersinks in progress

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After alodining and riveting

After alodining and riveting

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