billy's plans built sonex 1735

[wlarson861]

So I’m practicing the bolt method to do the rivets. Do the round head rivets have a flat on them from the bucking bar when set? Thanx again. Billy

Yes they will have flat spot in the middle. Or you can put a squeezer cup in the bucking bar and avoid the deformation. I had a rivet gun and an Avery C frame and used that.

[Rofomoto]

Yes they will have flat spot in the middle. Or you can put a squeezer cup in the bucking bar and avoid the deformation. I had a rivet gun and an Avery C frame and used that.[/quote]

So the flat spot is acceptable on the head?

[wlarson861]

The factory is the one who taught the bolt method at the builders training class. They built the prototypes that way if I remember right. In the class we built a leading edge cross section and riveted the spar caps with the bolt method. I asked about the flat spot and they said it was no problem since the material wasn't removed.

[Rofomoto]

The factory is the one who taught the bolt method at the builders training class. They built the prototypes that way if I remember right. In the class we built a leading edge cross section and riveted the spar caps with the bolt method. I asked about the flat spot and they said it was no problem since the material wasn't removed.

Thanx Bill....a few more practice ones and tomorrow the real deal.

[lstinthot]

Dont know if kit builders have to do this line up of parts but this is how I did it with a small bushing.

The new attach blocks are made of one piece. Since you have access the machine shop you could probably make the angle and attach block from one piece. it looks cleaner and saves a little weight.

[Rofomoto]

The new attach blocks are made of one piece. Since you have access the machine shop you could probably make the angle and attach block from one piece. it looks cleaner and saves a little weight.

Didn’t know that. I might have if I wasn’t so far along. Probably just save the weight of the two bolts. Good idea though.

[Rofomoto]

Ready to start riveting. Any specific order I should use to limit the sonex spar bow? And should all bolt be tightened before riveting?

[Rofomoto]

Just heard back from Kerry about my extra flush rivets and all good.

[lstinthot]

Ready to start riveting. Any specific order I should use to limit the sonex spar bow? And should all bolt be tightened before riveting?

We had very little bow in our spars and we had the bolts snug. And did every other rivet down the length of the spar. We built stands to hold the spars vertical between some braces. I think we started at the center on our first spar and found out those are much harder for us to learn on, then switched to the wing tip to learn. Once we got down to the center on the second and third spar we were pretty good at setting the rivets.

[Rofomoto]

We had very little bow in our spars and we had the bolts snug. And did every other rivet down the length of the spar. We built stands to hold the spars vertical between some braces. I think we started at the center on our first spar and found out those are much harder for us to learn on, then switched to the wing tip to learn. Once we got down to the center on the second and third spar we were pretty good at setting the rivets.

Thanx for the information. Ready to start now that I have all my concerns answered.