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Mistake on the aft deck

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Phil.Perry(at)netapp.com
Guest

Posted: Sun Jan 25, 2009 7:01 pm Post subject: Mistake on the aft deck

Hi  Everyone,

  

 I'm going to be sending  this to Vans too..

  

 Tonight I was riveting  the aft deck to the longerons of the tailcone.  In the process, I screwed  up a rivet and tried drilling it out.  At that point, Murphy slapped me on  the back for a second time and I managed to drill adjacent to the original  hole.

  

 The good news is that I  just barely touched the surface of the longeron, so it's just fine.  The  damage has been limited to the aft deck only.

  

 In the photo's below,  you can see the longeron on the bottom and you can see that I've polished out  the error to try and reduce the possibility of cracking  later.

  

 I've got a couple of  options.

     1) I  can drill for a 5/32 rivet, but that won't completely remove the  mistake.

     2) I  thought about drilling and replacing with an AN3 bolt - That might remove  it.

     3) I  thought about drilling the hole to be perfectly round (in the aft deck  only) and then placing rivets on either side of the hole.  In this case,  the screw up would be similar to a lightening hole.

     4)  Just drop a rivet in and keep going.

     5) Start over again with an entirely new aft deck.   (Obviously last resort if I can't find a reasonable repair)

     

     

 In the process of the  mistake, I've been trying to figure out what the real purpose of the aft  deck is.... (???)  I'm guessing it is designed to keep the longerons from pull apart  or pressing together in the aft end of the aircraft.

  

 Anyone have any  thoughts?

  

 Thanks,

 Phil

  

  

 http://s141.photobucket.com/albums/r51/philperry9/RV-10%20Build/?action=view&current=DSC_3522-1.jpg

 http://s141.photobucket.com/albums/r51/philperry9/RV-10%20Build/?action=view&current=DSC_3528.jpg

 http://s141.photobucket.com/albums/r51/philperry9/RV-10%20Build/?action=view&current=DSC_3523.jpg

  

  

  

 [img]cid:116123902(at)26012009-1AA8[/img]

  

  

 [img]cid:116123902(at)26012009-1AAF[/img]

  

  

 [img]cid:116123902(at)26012009-1AB6[/img]

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ricksked(at)embarqmail.co
Guest

Posted: Sun Jan 25, 2009 8:05 pm Post subject: Mistake on the aft deck

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pitts_pilot(at)bellsouth.
Guest

Posted: Sun Jan 25, 2009 9:19 pm Post subject: Mistake on the aft deck

Perry, Phil wrote:

 	  Quote: 	
		   Hi Everyone,

snip
	


 	  Quote: 	
		   I've got a couple of options.

     1) I can drill for a 5/32 rivet, but that won't completely remove 

 the mistake.

The drill will wander in the oblong hole, making a larger oblong hole.
	


 	  Quote: 	
		       2) I thought about drilling and replacing with an AN3 bolt - That 

 might remove it.

Gross overkill.  And gross looking also!
	


 	  Quote: 	
		       3) I thought about drilling the hole to be perfectly round (in the 

 aft deck only) and then placing rivets on either side of the hole.  In 

 this case, the screw up would be similar to a lightening hole.

Far more work than necessary.
	


 	  Quote: 	
		       4) Just drop a rivet in and keep going.

I vote for this one.  Should have been choice #1.  All you really need 
	


is  to attach the longeron to the aft deck.  Setting the rivet will 

mostly fill the hole.

 	  Quote: 	
		       5) Start over again with an entirely new aft deck.  (Obviously 

 last resort if I can't find a reasonable repair)

Only if you're a real purist.  I would bet money that there are quite a 
	


few holes just like yours out there with a std rivet in it. 

 	  Quote: 	
		   In the process of the mistake, I've been trying to figure out what the 

 real purpose of the aft deck is.... (???)  I'm guessing it is designed 

 to keep the longerons from pull apart or pressing together in the aft 

 end of the aircraft.

  

 Anyone have any thoughts?

Yep!  If that's the only boo-boo in your plane, you're way ahead of me.  
	


I'm no expert by any means, but I think you put yourself through far 

more stress and anxiety than necessary.  But, just to be on the safe 

side, maybe one of the experts will let us know if my reasoning is Ok or 

not!

Best of luck.

Linn

Linn

 	  Quote: 	
		    

 Thanks,

 Phil

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AirMike

Joined: 27 Feb 2007
Posts: 514
Location: Nevada

Posted: Sun Jan 25, 2009 11:06 pm Post subject: No expert here ......

What - you do not have a perfect plane like I have?????????



The aft deck is very important structurallyvto prevent excessive torsional stress on the tail feathers.



I am an absolute neophyte here but my suggestions (and I stress they are only my uneducated suggestions)  



1. drill it out and set a #5 rivet there. It will get a clean set, and it will fill out most of the hole.



2. Add a small doubler plate on top if it does not interfere with the mounting of the tail feathers. (I do not think that it does there.)



3. I do not like the AN3 bolt suggestion - hole too big - might compromise the longeron.



4. Finally - ask an A&P or one with an I/A. they do these kind of repairs every day.

To err is human - but to really screw up you have to be an airplane builder

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_________________
See you OSH '18
Q/B - sold.

ricksked(at)embarqmail.co
Guest

Posted: Mon Jan 26, 2009 7:12 am Post subject: Mistake on the aft deck

Mike,



If you don't like the AN-3 bolt you will hate the tail cone to main fuselage longeron connection...there are three of the on each side, counseling may be required for you to drill those holes and install the bolts to deal with all the hate you will build up inside!!  



There is also two AN-3's that hold the stabalizer mount angle to the deck. So Linn, it's already ugly!! besides the fairing will hide it in the end. Since the SB came out for the tailcone, I'd bet there are a BUNCH of rivets in that area on lots of -10's from drilling off the deck and redoing it.



Rick S.

40185



do not archive

---

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johngoodman

Joined: 18 Sep 2006
Posts: 530
Location: GA

Posted: Mon Jan 26, 2009 7:26 am Post subject: Re: Mistake on the aft deck

Phil,

An AN3 bolt would work IF you could keep it on the centerline of the longeron. I would do what AirMike suggested, go to a larger rivet.

Another option would be to go to a #8 screw. Just polish up the unwanted hole a little with a dremel to get rid of the possible crack starters, drill to a #8 screw, use a large washer on top if you can't stand anybody seeing it, and torque it with the red colored lock-tite. Screws are much stronger than rivets, anyway.

John

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_________________
#40572 Phase One complete in 2011

nukeflyboy

Joined: 05 Jan 2008
Posts: 162
Location: Granbury, TX

Posted: Mon Jan 26, 2009 10:17 am Post subject: Re: Mistake on the aft deck

Don't fret too much - we have all done this.  The standard method to deal with it is to go with a larger rivet.  Drill it out for an AN5 rivet.  If it is still a really ugly hole, then try an AN6.  The rivet will deform and fill the voids so a somewhat oval hole is OK.  The larger rivets have much bigger heads and will also hid the sin.

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_________________
Dave Moore
RV-6 built and sold
RV-10 built and flying

Phil.Perry(at)netapp.com
Guest

Posted: Fri Jan 30, 2009 7:33 pm Post subject: Mistake on the aft deck

I've been trying to send this fix out for a week and  it's been unsuccessful.  Apparently there is a problem with the e-mail, so  I just posted it on VAF.

  

 Here's the link.

  

 http://www.vansairforce.com/community/showthread.php?t=39140

  

 Phil

 

 

   From: Perry, Phil 

Sent: Sunday,  January 25, 2009 8:55 PM

To:  rv10-list(at)matronics.com

Subject: Mistake on the aft  deck

 

 Hi  Everyone,

  

 I'm going to be sending  this to Vans too..

  

 Tonight I was riveting  the aft deck to the longerons of the tailcone.  In the process, I screwed  up a rivet and tried drilling it out.  At that point, Murphy slapped me on  the back for a second time and I managed to drill adjacent to the original  hole.

  

 The good news is that I  just barely touched the surface of the longeron, so it's just fine.  The  damage has been limited to the aft deck only.

  

 In the photo's below,  you can see the longeron on the bottom and you can see that I've polished out  the error to try and reduce the possibility of cracking  later.

  

 I've got a couple of  options.

     1) I  can drill for a 5/32 rivet, but that won't completely remove the  mistake.

     2) I  thought about drilling and replacing with an AN3 bolt - That might remove  it.

     3) I  thought about drilling the hole to be perfectly round (in the aft deck  only) and then placing rivets on either side of the hole.  In this case,  the screw up would be similar to a lightening hole.

     4)  Just drop a rivet in and keep going.

     5) Start over again with an entirely new aft deck.   (Obviously last resort if I can't find a reasonable repair)

     

     

 In the process of the  mistake, I've been trying to figure out what the real purpose of the aft  deck is.... (???)  I'm guessing it is designed to keep the longerons from pull apart  or pressing together in the aft end of the aircraft.

  

 Anyone have any  thoughts?

  

 Thanks,

 Phil

  

  

 http://s141.photobucket.com/albums/r51/philperry9/RV-10%20Build/?action=view&current=DSC_3522-1.jpg

 http://s141.photobucket.com/albums/r51/philperry9/RV-10%20Build/?action=view&current=DSC_3528.jpg

 http://s141.photobucket.com/albums/r51/philperry9/RV-10%20Build/?action=view&current=DSC_3523.jpg

  

  

  

 [img]cid:838391103(at)31012009-0A1C[/img]

  

  

 [img]cid:838391103(at)31012009-0A23[/img]

  

  

 [img]cid:838391103(at)31012009-0A2A[/img]

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ricksked(at)embarqmail.co
Guest

Posted: Sat Jan 31, 2009 8:22 pm Post subject: Mistake on the aft deck

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