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Solid Riveting Problem

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sky_ranger161

Joined: 07 Jun 2006
Posts: 91

Posted: Tue Oct 24, 2006 3:01 pm Post subject: Solid Riveting Problem

Hi guys,

   

  I'm working on the solid riveting of my wing spars, and am having a strange thing happen while driving the smaller -5 rivets. The plans call for the factory rivet head to rest on the spar web, so the rivet goes through the web, through the spar cap, and through the spar cap angle - that's where you're supposed to drive the shop head. 

   

  I've driven all of the -6 rivets and they came out fine, but whenever I drive a shop head on the -5 rivets, the spar cap angle lifts slightly (see attached pic). I'm squeezing the parts together as I drive the rivet so there's no space in between them. I've only driven a couple of these smaller guys, but it seems to be happening with every rivet. In some places it's lifted more than the picture shows. I'm stumped.

   

  Anybody seen this?

   

  Thanks in advance for your help.

   

  Debo  Cox

  Nags Head, NC

  XL/Corvair

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pacificpainting(at)comcas
Guest

Posted: Tue Oct 24, 2006 3:20 pm Post subject: Solid Riveting Problem

Debo,

  

 I assume you did all the regular stuff. Deburr  everything. Clamp the pieces together. The rivet is the right size for the whole  etc,. I think the only time this happened to me was if there was something  between the layers or I didn't clamp the pieces tight enough or close enough to  the hole. Not sure though, it's been longer than a couple of days.

  

 Dave in Salem

  

  

 [quote]   ---

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cj.tremblay(at)videotron.
Guest

Posted: Tue Oct 24, 2006 5:17 pm Post subject: Solid Riveting Problem

Hi Debo,  

   

Are you sure that you put the head of the rivet on the thinner material side to rivet ?  

   

Chris  

         

  

De : owner-zenith-list-server(at)matronics.com [mailto:owner-zenith-list-server(at)matronics.com] De la part de Debo Cox

 Envoyé : Tuesday, October 24, 2006 7:01 PM

 À : zenith-list(at)matronics.com

 Objet : Solid Riveting Problem  

  

     

Hi guys,  

    

   

    

I'm working on the solid riveting of my wing spars, and am having a strange thing happen while driving the smaller -5 rivets. The plans call for the factory rivet head to rest on the spar web, so the rivet goes through the web, through the spar cap, and through the spar cap angle - that's where you're supposed to drive the shop head.   

    

   

    

I've driven all of the -6 rivets and they came out fine, but whenever I drive a shop head on the -5 rivets, the spar cap angle lifts slightly (see attached pic). I'm squeezing the parts together as I drive the rivet so there's no space in between them. I've only driven a couple of these smaller guys, but it seems to be happening with every rivet. In some places it's lifted more than the picture shows. I'm stumped.  

    

   

    

Anybody seen this?  

    

   

    

Thanks in advance for your help.  

    

   

    

Debo Cox  

    

Nags Head, NC  

    

XL/Corvair

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Ron Lendon

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

Posted: Tue Oct 24, 2006 5:41 pm Post subject: Re: Solid Riveting Problem

Debo,



How about taking a piece of the leftover spar cap and making a tool that will fit between the clecoes and have a notch or hole around the rivet.  Clamp that then rivet and see if it helps. I ran a couple of test pieces the other day and did not see that happen.  There are two different lengths of the 5 rivets.

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

Joined: 12 Jan 2006
Posts: 266
Location: Lindenwold, New Jersey

Posted: Wed Oct 25, 2006 5:06 am Post subject: Re: Solid Riveting Problem

Debo. Just looking at the one pic you posted I would suggest that the hole distances for those two adjacent clecos are not lined up. I.E. The hole to hole distance in the angle seen in the pic is greater than the hole to hole distance in the spar underneath. OK, so you may clamp close by as you drive the rivet but the vibration may be causing the two surfaces to "bounce against each other and rivet material is able to infiltrate the gap. I would suggest you remove all clecos in the assy except one near the middle. Now start adding clecos one at a time in every 4th hole but look critically at the flatness of the whole thing as you add each one. Any time you add a cleco and see that there is ANY seperation between the two parts (in between the two clecoes you last added) the hole alignment is off and you need to run a reamer through those holes. the difference will be small enough that you will not see it. If you continue as you were without fixind this problem your spar will probably end up wavy instead of flat. Actually it will not be wavy. It will WANT to be wavy but will be prevented from doing so by the strength in the angle. This means you will be setting up some small stresses in the assy. If you took two thin test strips a couple of feet long and had this alignment problem you would see the waviness clearly. The fix is easy and cheap. Buy a Reamer if you don't have one of that hole size and run iy though the culprit holes. This is not an uncommon problem but its hard to explain with a keyboard. Contact me directly by email if any of this is not clear.......Geoff...If you have any electrical problems, call me last.

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Ron Lendon

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

Posted: Wed Oct 25, 2006 9:21 am Post subject: Re: Solid Riveting Problem

Hi Debo,



Are you sure that you put the head of the rivet on the thinner material side to rivet ?



Just like Chris said.  Look at the NOTE on 6-W-3.

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