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RV-7 Construction Log
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Date:  11-30-2014
Number of Hours:  1.40
Manual Reference:  p. 8-10
Brief Description:  Rivet from Hell

I spent nearly an hour and a half on ONE rivet, and STILL didn't get it done! The rivet is on the left side where the forward side skin, aft side skin, aft bottom skin, two pieces of the F-706 bulkhead, and the aft end of the aft corner rib clip all come together. Yes, count 'em SIX layers of metal.

Somehow while fitting and coaxing all these parts into place, the hole got stretched a bit. I didn't notice this until this rivet clenched when Russ and I were riveting yesterday. Today, I tried fattening several AN426-3-7 rivets in my hand squeezer, and finally got one mostly straight. It promptly clenched also.

I then drilled the hole out to #30. Not having any "oops" rivets, I made one by grinding the head down on an AN426-4-7 on my scotchbrite wheel. That worked fairly well. I tried to back rivet with Karen and my 3lb bucking bar on the outside, but she wasn't strong enough to hold the bucking bar against the outside head and it ended up way proud on the outside, so I drilled the rivet out of this hole for the third time.

Fortunately, I still have a hole acceptable for a #4 rivet, so I made one more (see photos), but I'm going to wait for some more experienced help before I try to set it again...
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