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Old 03-20-2018, 06:15 PM
Scott Hersha Scott Hersha is offline
Join Date: Jan 2005
Location: Cincinnati, OH
Posts: 826

I think you need to get all of the chipped areas out of the holes you've drilled. A chip is a stress riser, and under the right conditions of temperature and load near the hole, it will crack. If additional countersinking won't get rid of the chip, you'll need to drill a larger hole with a clean cut. Countersink this hole, make it smooth, and if it's larger than the head of the installed rivet - not to worry.... use a countersunk washer to capture the rivet head and spread the load out to the hole. I made all my drilled holes in my canopy 2X the diameter of the rivet shank to allow movement. Not only countersinking, but polishing all cut and countersunk edges in the plexiglass will reduce stress riser areas, and allow easier movement with temperature changes. Make sure you use soft pull rivets for canopy installation if you are using rivets for attachment - not the best plexiglas attachment method by the way. You can't regulate the pull on the rivet, and even 'soft pull' rivets pull too tightly.
Scott Hersha
2001 RV-6 - sold 2005
2008 RV-8 Fastback - Sold 2016
RV-14 Wings - sold 2014
RV4 - Sold
Cessna 182RG - flying
New RV8 - Under construction
Cincinnati, OH/KHAO
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Old 03-20-2018, 07:46 PM
judoka5051 judoka5051 is offline
Join Date: Aug 2010
Location: Stuart, FL
Posts: 206
Default EAA videos!

There's an EAA video on this subject. He even shows you how to modify a standard bit. This is the method I use, and I drill hundreds of 9/32 holes in plexi every week.
Lance Logan
Stuart, FL
Plane at X58

Scratchbuilt Biplane
Preceptor N3 - Sold
Zenith Zodiac 601HD - Sold (good riddance)
Kitfox IV - Sold my share, but loved that plane
RV8A Sold! Loved the plane, but not the nosewheel!
RVX (RV6/4) Sold
RV8 Project purchased (Can't help myself)
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