3.5 Hours -
I finally started riveting the left flap. After doing a lot of searching for the best way to set these rivets, which have very limited access, the method I found was to use my 3″ pneumatic squeezer yoke as a bucking bar. Since the yoke is thin and heavy, it should work. Ironically, I found this method on Chad Jensen’s build site. It’s ironic because Chad is the guy that I bought my squeezer from!
A tip from another builder led me to use a squeezer yoke as a bucking bar in the flap.
Before riveting, I cut a small strip of drawer liner and placed it inside the flap against the aft spar. This will protect the aft spar from the bucking bar, and give me a place to rest the bar while riveting some of the rivets and not have to worry about scratching anything. However, once I started riveting, I only made it through about 6 rivets before the stand holding the flaps broke. So, I had to take a short break to build a new stand. This time, I used plywood instead of a plank.
A strip of drawer liner helped me protect/cushion the aft spar during riveting.
A few rivets in, my stands broke and I had to build new ones. This time, I used 3/4" plywood instead of a plank.
Once I built the new stand and got back to riveting, everything went relatively smoothly. The squeezer yolk/bucking bar made access a bit easier. After finishing all of the rivets on the main structure of the flap, I clecoed the forward spar in place and used blind rivets to attach the ribs to the forward spar. On the inboard rib, I screwed up one blind rivet (I didn’t set it flush due to very limited access), and made the situation worse when I drilled it out. The hole was enlarged so I’ll have to find a slightly larger diameter rivet to use here.
After setting the blind rivets, I started riveting the top skin to the spar. Once again, I had to find the best bucking bar for the situation. One of my new bars has a slanted face that worked perfectly. However, I only made it through about half of the spar before deciding to head inside for dinner. Finishing the left flap should only take another hour or so.
This bucking bar worked well for the forward spar rivets thanks to its angled face. All of the duct tape is to protect the flap parts from scratches and dings.
Almost done with the left flap!
