Title: 16-04 - Top Wing Skin Final Items
6/23/22 – 2.0h 6/24/22 – 2.8h 6/25/22 – 2.2h 6/26/22 – 3.1h It's taken a couple thousand rivets, but I feel like I finally have a clue on successfully bucking rivets. The rivets aren't 100% uniform yet, but they all meet standards without drilling out and replacing multiple misfires or major dings in the assembly. Practice makes perfect, and I think I'll be pretty good at this by the time the airplane is flying! This step consists of some final assembly items to complete the installation of the top wing skin. It starts by clecoing and then riveting the J-channels that run down the center of the skin along the complete span of the wing. The J-Channels slide into place pretty easily, and you have to make sure the outboard J-Channel sits above the inboard J-Channel. There is good access to buck the rivets, but pay attention to ensure the correct rivets get installed in the five holes where the J-Channels overlap. I used a couple of small nuts on the clecos to help pull the J-Channel tight to the skin before riveting, and was really happy with the way the parts end up riveted tightly together. The last item in this step is to attach the outboard aileron hinge brackets. The holes for the spar and a couple of holes for the rib web are pre-drilled so the bracket assemblies can be cleco'd in place. There is good access to match drill the remaining three holes for the rib web, and then all of the holes are drilled to final size. The plans specify an extended #30 drill bit to final drill the holes in the aft spar to provide clearance for the hinge bracket assembly. The plans remind you to remove the hinge brackets, debur the holes, and cleco the brackets back into place before riveting. Riveting the hinge brackets to the aft spar and outboard rib isn't as straight-forward as it looks. I thought I'd have relatively easy access to use the pneumatic squeezer. My plan was to use the squeezer to put the manufactured head on the inside of the wing rib first, leaving clearance for the manufactured head of the rivets to go on the outside of the assembly to the rear spar. I actually managed to get the bottom-most rivet on the rib squeezed (you can see the shop head on that one in the picture), but I think I was lucky to get that one done cleanly. The squeezer really does not have the required access to this area, and good luck if you have to drill out one of those rivets from inside the rib cavity! I switched to the rivet gun and bucking bar to set the rivets with the manufactured head on the outside of the assembly to the wing rib. I needed an extended rivet set, just like I needed an extended drill bit, for the rivets to the aft spar. A double-offset rivet set would also work in this area. I had to replace one of the rivets, but it came out cleanly and the rivets all went in without any other drama. [3x Rivet Gun, Swivel Mushroom Set, Regular and Extended1/8” Cupped Set, Tungsten BB-7 and BB-11 Bucking Bars, Pneumatic Squeezer with 1/8” Cupped Squeezer Set]


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