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  #1  
Old 03-26-2018, 10:35 PM
CubedRoot's Avatar
CubedRoot CubedRoot is offline
 
Join Date: Sep 2013
Location: Ooltewah, TN.
Posts: 548
Default Did I mess up my aileron leading edge?

Welp, I made a mistake drilling the counterbalance pipe on my left aileron tonight. I go into a bit more detail on my blog: http://theskunkwerx.com/rv7/assembli...-left-aileron/

Essentially, I did not have my drill at a good angle when I tried to match drill into the A-409 counterbalance pipe using the aileron leading edge skin as a guide. When I started drilling, I did not notice the bit "walking" on top of the pipe and it chewed up my the hole of my leading edge skin, elongating it. See these photos:

Here's the "results" of my bad drilling, with a ruler to show sizes.


And here is what it looks like with a cleco in the hole:


Its the second hole from the end, as you can see here:


Is this something I can fix, maybe with a larger rivet? I checked the actual pipe, and the drill only got a few thousands of the surface, just a barely scratching the surface of the pipe, so I am pretty confident the pipe is OK to reuse / fix. BUT, I am really concerned about that leading edge. I went ahead and countersunk the pipe and dimpled the skin to see what the blind rivet would look like in the hole, and it had some meat that it grabbed, but I wanted to run this by the brain trust here on the forums.

Is this fixable? Did I just ruin this nice leading edge? Can I just drill the hole larger and use a bigger blind rivet? If so, any size suggestions?

Here is a link to a really high resolution, large photo of the hole in the skin, dimpled, with a ruler next to it, in 1/32" markings to get an idea of how elongated the hole is. I'll just direct link to the image, so it doesn't cause this post to be huge: http://theskunkwerx.com/wp-content/u...316_203907.jpg

Thanks!
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  #2  
Old 03-27-2018, 12:20 AM
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Arie Arie is offline
 
Join Date: Jul 2010
Location: Dubai
Posts: 125
Default

Clean up the elongated hole, and drill two more holes, both sides of the bad hole aprox 1/2 inch from the bad hole, and put two more rivets in.
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  #3  
Old 03-27-2018, 08:07 AM
NavyS3BNFO NavyS3BNFO is online now
 
Join Date: Sep 2010
Location: Northern NJ
Posts: 74
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Quote:
Originally Posted by Arie View Post
Clean up the elongated hole, and drill two more holes, both sides of the bad hole aprox 1/2 inch from the bad hole, and put two more rivets in.
Did the same thing as you and Vans recommended the above fix. Build on!



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Last edited by NavyS3BNFO : 03-27-2018 at 09:15 AM.
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  #4  
Old 03-27-2018, 09:16 AM
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wirejock wirejock is offline
 
Join Date: Oct 2005
Location: Estes Park, CO
Posts: 3,028
Default Drill bushing

Buy a piece of brass tubing. Cut a piece about 1/2 the length of a #41 bit. Use it as a drill bushing.
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Larry Larson
Estes Park, CO
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Donated 12/01/2017. Plus a little extra.
RV-7A #73391, N511RV reserved (1,800+ hours)
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I cannot be, nor will I be, held responsible if you try to do the same things I do and it does not work and/or causes you loss, injury, or even death in the process.
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  #5  
Old 03-27-2018, 10:22 AM
PilotjohnS PilotjohnS is offline
 
Join Date: Jan 2016
Location: Los Angeles
Posts: 560
Default Some things are just not right to do

Some things are just not right to do. One of these is to never look at the aileron rivets of a friend's RV. Never do this... it is just not right.
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WARNING! Information presented in this post is my opinion. All users of info have sole responsibility for determining accuracy or suitability for their use.

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  #6  
Old 03-27-2018, 11:51 AM
mturnerb mturnerb is offline
 
Join Date: Apr 2015
Location: Ponte Vedra, FL
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Quote:
Originally Posted by PilotjohnS View Post
Some things are just not right to do. One of these is to never look at the aileron rivets of a friend's RV. Never do this... it is just not right.
Can we apply this rule to "all" rivets and other evidence of less-than-perfect workmanship?
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