I'm riveting my RV-7 flaps and having a few problems with rivet length. Some callouts on the plans seem too short and some too long. Wondering if anyone else has had similar issues and what you did about it? I tried searching VAF but haven't found anything about flap rivet lengths.
Specifically, on the short side, I found the rivets that go through both skins and either a spacer or a rib (4x FL-701 to FL-702 to FL-705 for example) are called out as AD3-3.5, but clearly AD3-4 is better. My LAA inspector made me drill those -3.5 rivets out and replace them with -4. In addition I found the AD3-4 rivets that fasten the bottom skin to spar to hinge are also a bit short. I went with those feeling that perhaps there is a reason due to the softness of the hinge material but I must admit I am not entirely happy with the thickness of the shop heads.
On the long side, the AD3-4 rivets that fasten the top skin to the spar seem too long. I'm in the process of setting those and finding that I'm drilling out about 50% due to rivets bending over severely. It does seem very odd that the length is called out the same for both top and bottom of the spar, where on the bottom there is a hinge and on the top there isn't.
Any thoughts or suggestions gratefully received!
Specifically, on the short side, I found the rivets that go through both skins and either a spacer or a rib (4x FL-701 to FL-702 to FL-705 for example) are called out as AD3-3.5, but clearly AD3-4 is better. My LAA inspector made me drill those -3.5 rivets out and replace them with -4. In addition I found the AD3-4 rivets that fasten the bottom skin to spar to hinge are also a bit short. I went with those feeling that perhaps there is a reason due to the softness of the hinge material but I must admit I am not entirely happy with the thickness of the shop heads.
On the long side, the AD3-4 rivets that fasten the top skin to the spar seem too long. I'm in the process of setting those and finding that I'm drilling out about 50% due to rivets bending over severely. It does seem very odd that the length is called out the same for both top and bottom of the spar, where on the bottom there is a hinge and on the top there isn't.
Any thoughts or suggestions gratefully received!