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RV-7 Construction Log
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Date:  4-28-2012
Number of Hours:  9.70
Manual Reference:  pp 7-1, 7-2
Brief Description:  Spar Nutplates - 1

Countersunk all rivet and screw holes for attaching nutplates to both spars, including the -4 center section attach and -3 inboard fuel tank z-brackets. I reamed all the the nutplate rivet holes to #40 and deburred. I drilled the nutplate screw holes out to #30 to fit the countersink pilot.

I didn't care for the thought of running a countersink pilot in the nutplate threads as recommended in the instructions, so I made a jig (Photo 1) with a # 30 hole for the countersink bit pilot, and two holes for rivets to be used as locator pins. The rivets can't protrude above the spar flange, as they would interfere with the foot of the countersink cage, so I used 0.125 stock to make the jig and 3-3 rivets (3/16" long). I taped the rivets in place, and used cleco clamps to hold the jig in place for countersinking (photo2). I had to add a different set of holes on the edge of the jig to allow room for it to be clamped to the #6 access cover nutplate holes (photo 3).

While actually drilling the screw countersinks, so much chaff was generated, that I couldn't tell when the countersink was finished. Karen was nice enough to come out and hold the shop-vac at the foot of the countersink as I was running it to keep it clear.
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Countersink pilot centering jig.

Countersink pilot centering jig.

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Jig in place, ready to countersink.

Jig in place, ready to countersink.

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Modified jig for holes along the edge of the spar flange.

Modified jig for holes along the edge of the spar flange.

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