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RV-7 Construction Log
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Date:  10-7-2012
Number of Hours:  7.60
Manual Reference:  
Brief Description:  Right Tank and Main Spar

Today I got the right tank skin and stiffeners ready to start sealing.

I started out by de-vinyling the exterior rivet lines of the skin, and deburring the interior and exterior of all holes in the skin and baffle. Karen then helped me with maneuvering the skin while I used my DRDT-2 for dimpling all of the skin holes except for the baffle holes (which I later countersunk), and the drain fitting holes (which don't get dimpled or countersunk). I also did not dimple the #8 screw holes, so as to make installation and removal of the tank on the spar easier for now.

For the baffle rivet lines on the tank skin, I set up the countersink cage about seven "clicks" deeper than flush to account for sealant. To provide centering for the countersink bit, I clecoed the baffle in place between the aft ends of the skin (photo 1). I clecoed every fourth hole to provide room for the cage between clecos. After each pass, I moved all clecos down one hole for the next pass, requiring a total of four passes to complete each side.

After countersinking the skin, and while I had the countersink cage out, I countersunk the lower outboard main spar holes that attach the leading edge and outboard main skins. To be deep enough for the dimpled 0.025 skins, I set the cage another seven "clicks" deeper than for the tank baffle.

After cleaning up all the countersink shavings, I scuffed and cleaned the interior rivet lines of the tank skin (photo 2). I used a stainless steel brush to make two crossing 45-degree passes down each of the rib, stiffener, and baffle rivet lines; and circular scuffs around the tank filler, and in the most forward part of the skin between the top and bottom rib flange lines. I then cleaned all the scuff lines with MEK.

After completing the skin, I also gave the stiffeners the same scuff and clean treatment (photo 3). I think I'm ready to start sealing.
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Setup for countersinking skin to baffle rivet lines.

Setup for countersinking skin to baffle rivet lines.

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Interior rivet lines scuffed, and in the process of being cleaned.

Interior rivet lines scuffed, and in the process of being cleaned.

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Stiffeners get the scuff and clean treatment too.

Stiffeners get the scuff and clean treatment too.

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