Date:	4-6-2009
Number of Hours:	3.00
Brief Description:	Main spar screw up
On the main spar, I started riveting with the AN470-5-6 rivets, inserting them through the main spar caps and then through the spar web - like the builder's checklist says (and like how we built the sample piece at the Sonex Workshop). Then I looked at a few other builder's websites, and they all had the rivets going through the spar web FIRST, then through the spar caps - opposite of what the instructions says. To get clarification, I sent an email to Sonex and they replied telling me that the way the other builders are doing it is right, namely, the rivets are inserted through the spar web first and then through the spar caps. Sonex said that doing it this way would prevent the gaps between the spar caps and the web. Unfortunately, I had already riveted about 35 the wrong way - and Sonex was right, the gap between the web and the caps wasn't very good. When I riveted the remainder of the spar with the rivets going the correct way, the web was nice and tight along the cap, much better. Then I drilled out the 35 rivets I put in the wrong way and since the holes were enlarged a little in drilling them out, I ordered the next size rivets. Should have them in a couple of days. Really only about a $15 screw up. Thought about just putting the same size rivets in the slightly over-sized holes, and it probably would have worked fine, but just knowing it was built that way would have made me think about it every time I flew it. I would always wonder…