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  #1  
Old 12-18-2017, 06:34 PM
Eztroller Eztroller is offline
 
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Location: West Linn,Or
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Default Countersunk too deep...

My question is replace the spar (HS 00903-1), or move on...? What surprised me was how fast the single flute countersinking cutter grabbed the material and took off!


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  #2  
Old 12-18-2017, 06:51 PM
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bkervaski bkervaski is offline
 
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Are you using a stop? There is a LOT of counter sinking, totally worth the $$

http://www.cleavelandtool.com/Thread.../#.WjhiuEtMGJY
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Old 12-18-2017, 06:54 PM
TX7A TX7A is offline
 
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Hey Brian

I don't know how thick the material is, but it may have a bearing on if it's too deep or not. I would certainly run it by Vans & see what they have to say.

Also, be sure to make a couple of test runs on some scrap with the countersink cage before you do the part. It may save you some grief.

Good luck

Sam
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Old 12-18-2017, 07:06 PM
Eztroller Eztroller is offline
 
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yes, I was using a cage but obviously screwed something up.... I have an email into VANS. I cant quite tell from reading ahead why the instructions call for countersinking here (page 8-2, step 5), but hopefully it wasn't a $75 mistake! Thanks for the replies.
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Old 12-18-2017, 07:15 PM
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wirejock wirejock is offline
 
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Default Countersink

Definately too deep for a rivet but often deep is relative to the part nesting in the countersink and location. Refer to Vans Mil-spec document for countersink dimensions and hopefully they will have good news for you tomorrow.
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Old 12-18-2017, 07:38 PM
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Saber25 Saber25 is offline
 
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Buy a new part and get a fresh start. Use the spar for test holes from now on before you start countersinking other critical areas. I always did a test on a spare piece to make sure the size and depth was correct before proceeding. Countersinking and dimpling are a fundamental skill in assembling an aluminum airframe and you'll have piece of mind when done correctly.

Cheers, Hans
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Old 12-18-2017, 09:08 PM
Tom023 Tom023 is offline
 
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Quote:
Originally Posted by Eztroller View Post
hopefully it wasn't a $75 mistake! Thanks for the replies.
Front and rear HS spars are $46 each. Shipping for one or both is $130 to Texas hopefully you can just go pick up.
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Old 12-18-2017, 09:40 PM
Eztroller Eztroller is offline
 
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Thanks for all of the feedback. I checked the mil-spec and it is definately too big.

Tom,

Thankfully its a 20 minute drive to Vans. Will wait to hear fron Vans, but expecting an early afternoon trip tomorrow.
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Old 12-18-2017, 10:44 PM
Aluminum Aluminum is offline
 
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Quote:
Originally Posted by Eztroller View Post
Thanks for all of the feedback. I checked the mil-spec and it is definately too big.
You may be able to go to next size up rivet. Check with mothership.
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Old 12-19-2017, 08:40 AM
NavyS3BNFO NavyS3BNFO is offline
 
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Location: Northern NJ
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Default Definitely too deep

I made the same mistake on my flap spars. After I made the mistake I found Section 5.5 where Van's recommends 7 'clicks' past flush when countersinking to accept a skin dimple. That corresponds to .007 past flush which is barely perceptible and a lot less than you think you need but it works.

I used my caliper to measure a test piece to set my csink cage then csunk the flap spars. Until I got comfortable I think I measured everyone. Then I measured every 5th one or so.

Proper depth



Picture of one too deep
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Last edited by NavyS3BNFO : 12-20-2017 at 08:00 AM.
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