Baffle mishap!

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Joe Parish
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Baffle mishap!

Post by Joe Parish »

I somehow managed to start to drill another hole next to an existing one in the baffle. I believe the drill bit must of jumped off to the side of the hole while trying to drill out a temporary rivet that was holding the tank attach bracket on. I had drilled the head off and removed the bracket and was trying to drill the remaining part of the rivet out of the hole. It was a #30 drill bit, the diameter of the started hole is about .100 wide. The baffle is only .032 thick. That drill tip is .038 long before it reaches full diameter. Just from the diameter of the hole I feel like I should replace the baffle? This is where the rib,baffle and tank attach bracket are riveted together. Looking for input?
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TomNativeNewYorker
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Post by TomNativeNewYorker »

why not a lap repair doubler?

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cjensen
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Post by cjensen »

From the look of the picture, I don't think you have anything to worry about. That drill divot doesn't appear to be deep enough to make any difference, especially with the hunk of metal that goes in that spot (if I'm thinking correctly, this is the nose of the rib...)

Can you post a wider shot of the area?
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Joe Parish
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Baffle mishap

Post by Joe Parish »

This is on the back of the baffle where the attach bracket will attach to the baffle. I will try to post a wider shot later. A doubler wouldn't work due to having to have it between the baffle and attach bracket. It would then be a different distance to the spar then the rest. The existing hole shown is one of the holes to attach the baffle and tank attach bracket. I hope that helps explain it better?
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bruceh
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Post by bruceh »

If you are talking about the rear tank baffle where the Z brackets get attached, then this would be hidden under the Z bracket eventually. The Z bracket would have a thin layer of sealant on it when it gets pop riveted down, so I think that would provide cover for this divot. If you are really paranoid, then I would fill this with a drop of JB weld, then sand it flush. Either way I don't think this is going to pose a leak problem, or a structural issue with the tank when it is filled with fuel.
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Joe Parish
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Baffle mishap

Post by Joe Parish »

Here is a wider view of the area. This is the rear of the tank baffle where the tank attach brackets will rivet to the baffle and tank rib and the other side of the attach bracket to the spar.
[img][img]http://i869.photobucket.com/albums/ab25 ... p001-1.jpg[/img][/img]
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cjensen
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Post by cjensen »

Ah...I was in the wrong spot. Build on my friend! That won't pose a problem in the least. If you do want to do something for sake of "feel good", I agree about dabbing some JB there, but it's not a structural or leak issue.
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dons
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Post by dons »

When I put mine on I used sealant between the z-bracket and baffle, so leaks would not be an issue. Also, you already have a pretty good doubler right there in the form of the z-bracket. My opinion is you would be hard pressed to find a real expert (unlike myself who is not) that would have any problem with you just building on with the way it stands.
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Joe Parish
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Post by Joe Parish »

Thanks for the input guys. I will either put some JB weld or just a little extra tank sealant around it. I was a little concerned about a possible stress crack forming from the drill point? I do not believe there will be much stress on the baffle? The brackets should carry most of the load.
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Post by cjensen »

Build on Joe... 8)
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