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Old 04-06-2012, 10:48 AM
Anna Anna is offline
Join Date: Aug 2011
Location: Passau
Posts: 56
Default Huge bulge in wing rear spar of an RV-8

Hello Together!

In the last time I have a real streak of bad luck…

By the installation of the gap filler of the wing, I made a huge bulge in
the rear spar of the wing. (See pictures) What shall I do now? I know the
rivet is to flat, too, but drilling it out could make everything even

Thanks for your help!

Best wishes,

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Old 04-06-2012, 11:09 AM
Mike S's Avatar
Mike S Mike S is offline
Senior Curmudgeon
Join Date: Sep 2005
Location: Dayton Airpark, NV A34
Posts: 14,023

Looks like you need to lighten up on your riveting.

What pressure are you running to the gun??
Mike Starkey
VAF 909

Rv-10, N210LM.

Flying as of 12/4/2010

Phase 1 done, 2/4/2011

Sold after 240+ wonderful hours of flight.

"Flying the airplane is more important than radioing your plight to a person on the ground incapable of understanding or doing anything about it."
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Old 04-06-2012, 11:12 AM
Kahuna's Avatar
Kahuna Kahuna is offline
Whelen LED Light Man
Join Date: Dec 2004
Location: Gold Hill, NC25
Posts: 2,373

It will be just fine.
You can do nothing and no one will know but you.

Originally Posted by Anna View Post
What shall I do now? Thanks for your help!

Best wishes,
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Old 04-06-2012, 11:28 AM
flion's Avatar
flion flion is offline
Join Date: Dec 2007
Location: Flagstaff, AZ
Posts: 2,466
Default Second that

Originally Posted by Kahuna View Post
It will be just fine.
You can do nothing and no one will know but you.
Your best fix is to leave it alone.
Patrick Kelley - Flagstaff, AZ
RV-6A N156PK - Flying too much to paint
RV-10 14MX(reserved) - Fuselage on gear
EAA Technical Counselor #5357
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Old 04-06-2012, 05:06 PM
Pmerems's Avatar
Pmerems Pmerems is offline
Join Date: Jan 2006
Location: Tucson, AZ
Posts: 800
Default Not too bad

I would remove the rivet and flatten the bulge using wooden blocks (hardwood) and a hammer. You may need a helper to hold the blocks. If you remove the rivet carefully you shouldn't damage the hole. Then set another rivet. Possibly practice on some scrap first.

If this is the worst thing that happens when building consider yourself fortunate.
Dream it, Build it, Fly it

Paul Merems (EAA Tech Counselor, EAA Sheetmetal Workshop Instructor/Volunteer 12 yrs)
ExperimentalAero-HANGAR BANNERS
RV-7A (Flying since 2010)/RV-4 (sold 1990)
Tucson, Arizona 85749
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Old 04-06-2012, 05:07 PM
Walt's Avatar
Walt Walt is offline
Join Date: Aug 2005
Location: Dallas/Ft Worth, TX
Posts: 4,619

If it was me, I'd probably remove the rivet for inspection, gently "tap" the area to make it flatter and then re-install the rivet. The head of the rivet is so mashed that any tension on it would likely shear it off anyway (I know it "probably" loaded in shear). I would also send the pics to Van's engineering just to get their blessing, after all we are talking about the rear spar here. Damage to the spars should not be taken lightly.
Walt Aronow, Dallas, TX (52F) RV7A, IO360, C/S, 1500+hrs

EXP Aircraft Services LLC
Specializing in RV Condition Inspections, Maintenance, Avionics Upgrades
Dynamic Prop Balancing, Pitot-Static Altmeter/Transponder Certification
FAA Certified Repair Station, AP/IA/FCC GROL, EAA Technical Counselor
Authorized Garmin G3X Dealer/Installer
RV7A built 2004, 1700+ hrs
Website:, Email:, Cell: 972-746-5154
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