Riveter head mod

Plan Note:

The riveter head required modification per the plans to create a domed head out of a flush head rivet. The plans suggest the tip needs to be annealed to be drilled but the tip on the Harbor Freight Hand Riveter drilled without being annealed. The initial attempt with a 1/4", 135 degree drill bit was too deep and created more of a dome than we deemed desireable. Some of the tip (.015?) was remove and a 5/16" bit was used to shallow out the depression. This change created a flatter rivet head.

Bulkhead E2, F and corners

Build hours: 37
Bulkhead E2 was cut from .025 2024T3. The bulkhead was cut, trimmed and filed as before. A 1 1/2" hole saw was then used to cut the lightening holes. The tabs were bent forward and the lightening holes were flanged rearward with a flanging die made from particle board. The flanging process created a bow in the bulkhead which should come out when installed otherwise the bulkhead will have to be remade.
Bulkhead corner tabs were made for bulkhead E and installed. Both bulkheads had some oilcanning after all the flanging so before installing the tabs, the bulkhead was C clamped back to the original form. One E bulkhead was completely drilled and clecoed before riveting and the oilcanning remained. The other was drilled, clecoed and riveted one corner at a time an exhibited almost no oilcanning. The 040 for bulkhead F was rough cut and the rudder and elevator holes were cut with a 2" hole saw. Scrap one piece of .040 when I pulled out the 2 1/8" hole saw! The .040 was tough to cut even with the 14" Andy Snips, luckily there is not a lot of .040 or thicker components!

Tools Used

Tool List Updated 8/29/2007

Hand Tools:

14" Andy Snips (Malco MC14N - this size is really needed on the .040 matl)

10" Tin Snips (Wiss)

10" Fine File

Countersink - small hole deburring and rivet countersinking

(100 degree required for AN countersunk rivets)

( 120 degree for Cherry-Lok countersunk blind rivets)

Deburring Tool - large hole deburring

Homemade 48" Leaf Brake

http://cwsnyder2001.blogspot.com/2007_06_01_archive.html

Homemade 17" Heavy Duty Leaf Brake

http://cwsnyder2001.blogspot.com/2008_08_01_archive.html

Dead Blow Hammers (Harbor Freight)

Cleco Pliers

Power Tools:

Drill Press

Dewalt 12V Drill

Band Saw - cut out bulkhead forms, could have used jigsaw

JigSaw - cut out bulkhead forms

Belt Sander - cleanup bulkhead forms

Air Tools:

Air Nibbler - rough cut inside bulkhead patterns

Air Riveter for blind rivets - Harbor Freight

Air Drill - good for tight spaces

Air Angle Drill - good for tighter spaces

Air Hammer - can be used for riveting on the cheap

(A model with 3000 bpm or less should be used)

Rivet Gun - ATS 2x from Aircraft Spruce

(because I want to be a REAL airplane builder:))

Misc:

1/8", 3/16", 1/4" drill bits

Unibit/Step Drill

1 1/4" hole saw

1 1/2" hole saw
6" Vise

2" C Clamps - 16+

4" C Clamps - 4+

Batting gloves

Compass

Sharpie Ultra Fine Pens

(Red shows up the best, also, it doesn't look like a shadow when viewed through a hole)

6" Machinist Rule

Bucking bar from A&P school days

3/32" Clecoes - 300 (Aircraft Spruce)

1/8" Clecoes - 200 (Aircraft Spruce)