So how bad is this?

[JohnR]

Well it has been a couple of weeks since I've been in the shop due to work and I finally got a little time tonight.

I'm working on the rear spars for the wings. I trimmed the stifeners and they came out just as they needed to. So then I go to the stiffener that has the hole for the aileron rod to pass through. I clekoed it and put in my #30 bit and match drilled it to the rear spar. Used the unibit to start tge aileron hole and finished it up with the Dremel. Didn't take long and worked great.

I took it apart to eburr and the holes in the rear spar looked to big. First I thought I had picked up the wrong size bit, but I checked and it was the correct bit. The only thing I can think of is the bit is dull and wondered around some before biting into the stiffener. The stiffener holes are all good and measure correct but the rear spar the holes measure about .138 - .141 and a rivet wallows around in them some.

So, any opinion on this? I would guess that the rivet will expand enough to fill this approximately .020 gap but would sure like some reassurance. I really don't want to buy a new rear spar. If Van's was around the corner it wouldn't be a big deal but I'm afraid the freight would cost more than the part.

[bmurrish]

If the hole is way too big you could use a wider rivet. I bought some wider ones from Van's to do the tooling hole on the outboard tank rib.

[jim_geo]

Yup a bigger diameter rivet is what's called for.

[captain_john]

One thing that Wicked Stick has shown me is to slightly "pre squeeze" a longer rivet, thereby making your own "oops" rivet. It aids in proper bucking and assures a better fit and finish.

Give that a try!

CJ

[cjensen]

I really don't want to buy a new rear spar. If Van's was around the corner it wouldn't be a big deal but I'm afraid the freight would cost more than the part.

Don't do this!! Big money wasted...I forth what the three before me have said. Use a larger rivet or presqueeze one. I've done it several times. The called rivet would fill the .020 gap as well...

[JohnR]

Thanks to all. I will probably pre squeeze some rivets for this as it really isn't that bad. It just really surprised me when I saw it. Seems everytime I am to busy to work on the plane for a short period of time I end up with some little thing like this. It goes much better when I can get in an hour or two a night.

Thanks again.

[jim_geo]

Even if you just walk into your shop and look around at what you're doing every day or night just to stay up on the project makes a restart much easier.

[JohnR]

Jim, I would agree and do try to get into the shop about everyday, just haven;t had time to do much other than look at things for a couple of minutes. My son is a senior and graduates on May 21. I've been having to spend time doing things my wife has plannned for me as far as getting a party planned and all that also.

One nice thing is that I have been very busy and that helps pay for airplane parts!

Once Luke is off to Texas this fall for colege though we will have an empty nest so should have more time to work on banging rivets.