extra dimpling hole

n701vb · Post by **n701vb** » Tue May 29, 2007 7:32 pm

Hi,

I'm sure someone else has done this too somewhere along the way. I put an extra hole in my elevator skin while dimpling (actually, my helper moved as I was striking the dimple die!). What options do I have? I'd hate to reorder the whole skin if this can be salvaged.

the hole is about .15 inches from the center of the rivet hole for the stiffener. The hole is about .065 inches in diameter. Is this something that can be filled in with bond or something during the painting process, or is there another fix available to avoid having to reorder a whole new skin?

The hole is about in the middle of the elevator skin (third hole from the leading edge).

Here's a photo:

http://websites.expercraft.com/vinceb/i ... g_id=17410

Thanks![/img]

captain_john · Post by **captain_john** » Tue May 29, 2007 7:40 pm

Patrick,

This is a common mistake. I think Van would tell you to drill it clean and continue -or- replace the skin if it bothers you. Call them anyways.

Mind you, there is no better time to replace the skin than now but, you still could mess up the new one even greater!

Choice is yours!

CJ

painless · Post by **painless** » Tue May 29, 2007 7:51 pm

Is this on the top or bottom of your elevator? No matter, just that if it is on the bottom, that fact can often times make you feel a little better.

Definitely no reason to order another skin. I would first of all clean up the new hole as best you can with a deburing tool so you don't develope a crack. You could even go so far as to run a drill bit through it to make it concentric.

Next, make sure you can get your stiffener to lay flat on the skin in this area. You can take a couple flush sets and put one in the base and one in the arm of your dimpler (did you use the DRT thing you young bucks have now or just an Avery C-frame?) Gently tap the offending dimple flat enough to allow that stiffener to sit flush. This really shouldn't take much.

Then I would go ahead and rivet your stiffener. It looks as if the siffener will back up that hole just enough for some filler to be placed over it. You will probably find that your flush set will even out the skin a bit too.

Done deal. Believe me, this hole will become extremely insignificant to you as your project progresses.

Regards,

Wicked Stick · Post by **Wicked Stick** » Tue May 29, 2007 10:54 pm

So far, I've avoided this mishap. But if it were me, I suppose I'd order a new skin. That hole looks too close to the correct hole for my comfort zone.

Ultimately though, the decision is yours.

svanarts · Post by **svanarts** » Tue May 29, 2007 10:58 pm

Just curious Jeff. What kind of filler do you use? Super-Fil or silver amalgum? Do you ever get them mixed up?

Sorry, couldn't resist.

TomNativeNewYorker · Post by **TomNativeNewYorker** » Tue May 29, 2007 11:26 pm

I would cut out a section of the skin and make a flush patch repair.

cnpeters · Post by **cnpeters** » Tue May 29, 2007 11:58 pm

I did a couple of those - flattened them back down, deburred with a round jeweler's file, then dimpled the regular hole as planned. I will fill later before paint. If a crack develops to the rivet, great, it is already stop drilled. Due to design redundancy, there will be no structural issue. Many have done this per past VAF forum threads, and everytime this has been posed to Van's, they have said to clean it and move on. Of course, you should ask them to hear from the horse's mouth.

painless · Post by **painless** » Wed May 30, 2007 8:46 am

Scott:

Come to think of it, Amalgam would work great! Same color and everything! If anybody needs some, I have plenty of it left over. Hardly use the stuff anymore.

I *have* almost asked my assistant for a bucking bar tho....

n701vb · Post by **n701vb** » Wed May 30, 2007 6:03 pm

Thanks guys. I checked with Vans and they said pretty much the same thing. It's not structural, just cosmetic. He suggested filling with superfill or body filler to fill the hole after the stiffeners are on. As long as I clean out the hole enough, I wouldn't think I'd have too much to worry about the hole cracking or spreading over time.

I assume body filler is something I could easily pick up at an auto parts store?

Vince

painless · Post by **painless** » Wed May 30, 2007 6:50 pm

Don't use something like Bondo Vince. Get some Superfil from Aircraft Spruce.

Either that or just leave it, make a note of it, and then have your painter take care of it for you. Just make sure that you specify to him that you want such things taken care of prior to final color coats.

svanarts · Post by **svanarts** » Wed May 30, 2007 7:28 pm

painless wrote:Scott:

Come to think of it, Amalgam would work great! Same color and everything! If anybody needs some, I have plenty of it left over. Hardly use the stuff anymore.

I *have* almost asked my assistant for a bucking bar tho....

Hmmm.... How well would that stuff stick to aluminum? Can it be polished? I have a friend that is painless too. I wonder if he's got any sitting around? Would there be any corrosion? I know when I bite down on aluminum foil... YEEHAW!

Interesting idea though.

painless · Post by **painless** » Wed May 30, 2007 8:56 pm

The FAA would probably put the kabash to it....All that mercury in it you know....

I had thought of not painting my RV and calling it the "Flying Silver Amalgam".

Glad I didn't!