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Scratch built spar finished

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TxDave

Joined: 22 Jul 2006
Posts: 168
Location: Temple, TX

Posted: Fri Sep 22, 2006 10:23 pm Post subject: Scratch built spar finished

For all you scratch builders who are intimidated by the prospect of building your spars, I have good news. It isn't that hard. I finished my right spar today. With the lessons learned from that experience I figure the left one will take 1/3 the time to complete. Special thanks to David Barth, Randy Bryant, and Herb Heaton, who all crossed this bridge before me. Their advice was invaluable. Also thanks to Debo Cox for helping me figure out a way to bend my spar cap angles. And of course, thanks to Mr. Scott Laughlin for always answering my stupid questions.



Dave Clay

Temple, TX

601 Scratch Builder

http://www.daves601xl.com

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leinad

Joined: 19 Sep 2006
Posts: 283
Location: Central Virginia

Posted: Sat Sep 23, 2006 4:28 am Post subject: Re: Scratch built spar finished

Dave,

Thanks for the post and the web sight.

I recently finished scratch building my spars (I thought).  When reviewing the Zenith instructions I realized I had used soft AN470A-6-- rivets, not the required AN470AD-6-s.  Ugh!  I had remove them all, and am now waiting for the correct rivets from ACS.. on back order.  Oh well, there are lots of other parts to make.

I relate this for those scratch builders who might make the same mistake.

Again, I love the web sight!  Keep up the good work.

Dan Dempsey

_________________
Scratch building XL with Corvair Engine

naumuk(at)alltel.net
Guest

Posted: Sat Sep 23, 2006 6:55 am Post subject: Scratch built spar finished

Dan-

    You had me really worried with your post, and was contemplating suicide 

until I reviewed the HDS plans. They call for ADs with no suffix.

    I sure would have asked Zenith if "Straight" ADs were acceptable for 

your project before tearing my spars back down!

                           DEFINITELY ARCHIVE!!

Bill Naumuk

HDS Fuselage

Townville, Pa

---

TxDave

Joined: 22 Jul 2006
Posts: 168
Location: Temple, TX

Posted: Sat Sep 23, 2006 7:36 am Post subject: Re: Scratch built spar finished

Hey Bill,

I believe Dan was correct. According to AC 43.13-1B page 4-17 the AN470 "A" rivets have a shear strength of 10,000 psi and a bearing strength of 25,000 psi. The AN470 "AD" rivets have a shear strength of 30,000 psi and a bearing strength of 100,000 psi. The XL plans do call for the "AD" rivets. I almost made the same mistake as Dan but was saved by the good folks at ACS. By the way, Bill, I always enjoy reading your postings. You're an asset to this forum.



Dave Clay

Temple, TX

Ch601XL scratch builder

http://www.daves601xl.com

naumuk(at)alltel.net
Guest

Posted: Sat Sep 23, 2006 12:35 pm Post subject: Scratch built spar finished

Dave-

    I thought all spar rivets were AD. Dan said his plans called for AD-S. 

The "S" is what threw me.

    Regardless, I'm just a happy camper that I don't have a batch of the 

wrong rivets buried in my outboard wings. I don't think I could take having 

to rebuild them again. Not when I have the rear fuse in clecos, ready to 

tear apart and polish the sides and bottom tommorow.

    Sometimes I'm an asset, sometimes I use the list as depression therapy. 

Whatever it takes to make progress.

    Good building.

Bill Naumuk

HDS Fuselage

Townville, Pa

---

Ron Lendon

Joined: 10 Jan 2006
Posts: 685
Location: Clinton Twp., MI

Posted: Sat Sep 23, 2006 12:37 pm Post subject: Re: Scratch built spar finished

Nice work Dave,



I just logged in to ask if the 5/16 attachment holes should go in now (laying out spars) or at assembly.  I noticed from your pictures that you didn't put them in yet, so neither will I.  I will just save it for latter.



This list saves me yet again!

_________________
Ron Lendon
WW Corvair with Roy's Garage 5th bearing
CH 601 XLB
N601LT - Flying
http://www.mykitlog.com/rlendon
Corvair Engine Prints:
https://sites.google.com/site/corvairenginedata/

planejim(at)bellsouth.net
Guest

Posted: Sat Sep 23, 2006 1:35 pm Post subject: Scratch built spar finished

Dan,



You will find that you will have to have quite a bit heavier bucking bar and 

at least a 3X gun for those AD-6 rivets unless you are using a press to set 

them.



Those "A" rivets sure were easy to set though weren't they?



I'm glad you caught this. It would have been a bad situation if you hadn't. 

I know of a Thorpe T-18 that came apart in flight because the builder did 

the same thing but no one caught it!



Jim Hoak



do not archive



Subject: [Norton AntiSpam] Re: Scratch built spar finished

 	  Quote: 	
		   I recently finished scratch building my spars (I thought).  When reviewing 

 the Zenith instructions I realized I had used soft AN470A-6-- rivets, not 

 the required AN470AD-6-s.  Ugh!  I had remove them all, and am now waiting 

 for the correct rivets from ACS.. on back order.  Oh well, there are lots 

 of other parts to make.

 I relate this for those scratch builders who might make the same mistake.

 Again, I love the web sight!  Keep up the good work.

 Dan Dempsey



 --------

 Scratch building XL with Corvair Engine





 Read this topic online here:



 http://forums.matronics.com/viewtopic.php?p=63374#63374

waj(at)quik.com
Guest

Posted: Sat Sep 23, 2006 3:06 pm Post subject: Scratch built spar finished

Hello group ,you may want to keep in mind that all AD rivets have a small 

dimple in the center for identification ,soft are plan ,no dimple. Wade

---

leinad

Joined: 19 Sep 2006
Posts: 283
Location: Central Virginia

Posted: Sat Sep 23, 2006 5:13 pm Post subject: Re: Scratch built spar finished

waj noted:



 Posted: Sat Sep 23, 2006 3:06 pm    Post subject: Scratch built spar finished   



--------------------------------------------------------------------------------

 

Hello group ,you may want to keep in mind that all AD rivets have a small 

dimple in the center for identification ,soft are plan ,no dimple. Wade 

--- 



However, the soft rivets I had looked as if they were dimpled.  In the center of every rivet head is a tiny 3 or 4 digit number.  I can't read it, but originally I thought it was the dimple.  But the package cleary says AN470-A, not AD..  

Sorry for the earlier confusion the --s was meant to signify plural.

_________________
Scratch building XL with Corvair Engine

naumuk(at)alltel.net
Guest

Posted: Sat Sep 23, 2006 5:31 pm Post subject: Scratch built spar finished

I realize that now, but I'm getting so gun-shy....

    You had no choice but to tear everything back down if you used A instead 

of AD rivets. Been there, done that. Not for the wrong rivets, but the wrong 

spar cap material. 2024 instead of 6061. Thought it was a little too shiny. 

Can't remember if it was ACS's or Wick's mistake.

    Like the desk sarge on Hill St Blues used to say- "Be careful out there, 

folks".

Bill Naumuk

HDS Fuselage

Townville, Pa

---

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