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RV-7 Construction Log
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Date:  9-1-2012
Number of Hours:  0.00
Manual Reference:  pp 7-7, 7-8
Brief Description:  Left Fuel Tank Complete! - Part 2

Next I clecoed the baffle to the interior ribs in every other hole. I had to use a pin punch to maneuver the parts slightly so that the AD-41H rivets would go in the outer holes. After setting the top and bottom baffle to rib rivets, I went back and attached the z-brackets after cleaning and applying a thin layer of sealant around the holes in both the baffle and the brackets. I had earlier numbered the brackets on the inboard face of the web so I could properly orient them on installaton. After clecoing but before setting rivets, I cross-checked the bracket orientation against the plans; all good. Using the "Checkoway" method of drilling the brackets, along with the use of a "POP" brand rivet puller, I had 1/32 to 1/16 inch clearance between the head of the tool and the z-bracket web. After setting all of the pulled rivets, their heads got encapsulated with sealant.

On the baffle to end rib rivets, I couldn't get the pneumatic squeezer adjusted to properly set the 1/8 rivets, so I shot and bucked these, no problem. For the inboard z-bracket I would have had to do this anyway, due to the orientation of the flange.

I had planned on going down to Paul Rosales' movie night, but by the time I got to this point, it was too late, so I just decided to go ahead and finish the tank. I mixed up a small batch of sealant and encapsulated all skin to baffle rivet shop heads, and laid a thin layer of sealant along the baffle to skin seam before removing the making tape. I then encapsulated the end rib rivets and filleted the thick beads of sealant in the corners of the tank.

I then scuffed and cleaned the faying surfaces of the tank access cover and interior end rib where the cover attaches. I spread a liberal layer of sealant on both parts, and attached the cover using torx-head screws from McMaster-Carr instead of the supplied phillips screws.

(Continued next entry.)
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Well-formed bead fillets inside tank.

Well-formed bead fillets inside tank.

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Access cover ready for installation.

Access cover ready for installation.

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Cover attached with torx-head screws, and tank mounted on spar.

Cover attached with torx-head screws, and tank mounted on spar.

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