Daily Archives: April 13, 2014


Fuel Tanks 23 (2.0 hrs)

About a month ago, I made a major mistake on my fuel tanks. Like a complete idiot, I installed the right z-brackets on the left tank and vice versa.  I was mortified when I realized what I had done.  I decided to allow all of the sealant to completely dry so that I would have the best chance of retrieving the rivets from inside the tank.  If the sealant were still tacky, I would have no luck.

I was dreading drilling out the pop rivets.  I thought they would be more difficult than normal rivets.  It turned out to be super easy.  I drilled out all of the pop rivets on both tanks in probably about 20 min.  The center punch finished the job.

All that remained was to retrieve all the pieces from inside the tanks.  I should be able to just shake them out… right?  Nope.  Well then, no worries, I have a telescoping magnet and mirror… this should be no sweat!  Wrong again.  There should be 25 pop rivets in each tank (50 total).  After a good hour and a half of shaking, magnet wielding, and sticky tape ball fishing, I had 17.  They don’t even rattle anymore.  So yeah, now I’m not sure what the next step is.  If I have to take that baffle off, I’m going to be sick to my stomach as that is A LOT of work.  With that many rivets to drill out, the likelihood of messing one up also goes up.

I’m inclined to say f&$# it.  Thats what a fuel filter is for, but I’m probably going to consult Van’s and maybe the forums first. I don’t like the idea of a potential clogged fuel line 10 years from now.  *Edit.  I posted to VAF here. 20140413-181241.jpg

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The 17 pieces that I was able to retrieve. 20140413-181258.jpg


Wings 21 (11.0 hrs)

Spring has finally arrived with a beautiful weekend perfect for working on the plane.  I finished up de-burring the edges of the remaining wing skins.  Next I used acetone and cheesecloth to prepare all of the surfaces for priming.  Cheesecloth is indispensable for this purpose.  No lint, no dust, no dye. 20140412-210722.jpg20140412-210730.jpgIt took a lot of primer for all of the leading edge ribs, eight wing skins, and the leading edge skins!  Certainly the most primer I have ever used in one session before.  I did break it up into three priming sessions so that I could move parts around in between. 20140412-210802.jpgA few coat hangers repurposed make a great way to prime skins. 20140412-210819.jpg20140412-210827.jpgI didn’t want to prime the left outer bottom skin until I had set up the Gretz Pitot tube mount I had bought.  20140412-210848.jpgHere is the backing plate in place after match drilling to the spar. 20140412-210858.jpgThis was the first angle I used. I wound up abandoning it after the edge distances were out of spec. 20140412-210936.jpgWhen setting the aluminum angle in place, cleco the skin and the backing plate in place.  This will allow you to perfectly place the angle using a couple of c-clamps. 20140412-210943.jpgI measured out where I wanted to put the attachment rivet holes. 20140413-150457.jpgHere is the backing plate after all of the rivet holes have been drilled. I have it clamped in place in order to match drill the aluminum angle. 20140413-150514.jpgHere is the new attachment angle.  Overkill, but I prefer to use scrap when available. 20140413-150522.jpgUsing my large blue marker, I colored in all of the area of the skin that needed to be removed. 20140413-150535.jpg20140413-150545.jpgI used a unibit to remove as much as possible and then filed the remainder flush. 20140413-150602.jpg20140413-150611.jpgHere is the bracket in place. 20140413-150621.jpg20140413-150634.jpgWith the pitot tube bracket complete (except for the nut-plates), I could prime the remaining skins and pitot hardware. 20140413-150644.jpg20140413-150709.jpg

The end results. 20140413-181317.jpg

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