Bad Dimple on Horiz Stab Skin

[plbarrett2004]

Seems like I'm making a lot of mistakes. Well, here's my latest one:

Doing my first dimpling on the HS 801 Skin and while I thought I had the skin on the dimple... it slipped. The "new" dimple is right next to the hole. This hole is in the center on the rear edge for attaching to the rear spar. I've included some pictures. Unfortunately, I cannot simply stop drill and continue.. neither a 3/32" or a 1/8" rivet will completely cover it. I don't feel that one bad dimple requires a new skin, but I'm not sure how to best implement a fix.

Based on the other threads I've read, this is what I'm currently thinking to do. I'm hoping the experts on here can steer me in the right direction...
1. Stop drill the crack.
2. Drill the original hole to 1/8"
3. Dimple with 1/8" die.
4. Rivet with 1/8" rivet??
5. Add some type of filler…???[/list]

I've seen alternate solutions such as adding another rivet next to the orginal hole, or leaving the rivet out entirely. I think any rivet has more strength than no rivet, so I don't like the latter. Maybe order a new skin.. $100!!!




Here is a photo with a standard 3/32" rivet in the original hole.

[captain_john]

Peter,

I think you are on the right track!

Try the process you described and see how it works out.

I think it will be just fine.

Another option would be to flatten it out and put a rivet to each side of the mistake and putty it up when you paint it!

Keep us posted! Press on!

CJ

[bullojm1]

Peter,

Here's what I would do:

1) stop drill the crack
2) flatten out the skin using your hand squeezer
3) dimple the hole where it's supposed to be.

Don't even think about replacing the skin. If when your all done with the build and this still bothers you, replace the skin!


It might be worthwhile to call vans up and get their opinion tomorrow morning. I always take their advice over anything I hear on the forums.

Good luck!

[plbarrett2004]

Mike,

I highly doubt I will replace the skin... In the end as long as I repair it well it shouldn't be more than cosmetic. I like your idea... Less work than increasing the rivet size.

What's really bad, is I made this same mistake during the practice kit only with the pneumatic squeezer... Guess I need to learn!

Thanks!
Peter

[Bob Barrett]

Peter, Most of us Barrett's have to learn the hard way! When I began my RV-6A, I promptly screwed up the Horizontal main Stabilizer and during ordering the new one I asked how often someone had to replace kit parts. This was in 1999 and they said the average builder spent between $300 and $400 in replacement parts. I didn't keep exact count but I know I used up more than $400 and then some other things caused me to do some things a more complex and expensive way. Just remember your are building the airplane for your personal education. By the time you have it flying, you will have a better knowledge and understanding of that airplane than any other airplane you have ever flown! (Unless you have previously built another airplane.)

[plbarrett2004]

So the response from Van's recommended the fairly textbook approach. Drill it out, and put a new rivet on either side. Put a rivet in this hole if I like, for looks and use JB Weld to secure it. The last sentence told me more than that. "Replace the skin if you don't want your buddies to see what you did." In my mind, its a non-issue that will only affect my ego.

I know I'm over analyzing this problem, but two additional rivets seems excessive. Either way, I followed Mike's suggestion tonight and pictures of the result are below.

Here's what I would do:

1) stop drill the crack
2) flatten out the skin using your hand squeezer
3) dimple the hole where it's supposed to be.

I'm still debating if I want to do the two additional rivets. I'm thinking I could hide those two rivets with some filler prior to painting and leave the original one showing...

[captain_john]

Brilliant!

Who else said to put a rivet on either side?

CJ

[plbarrett2004]

CJ... thanks. I did what Mike recommended for the original rivet, and after sleeping on it, I'm also going to put two additional rivets in like you and Van's recommended. The original rivet will get a JB Weld treatment to clean it up and keep it secure. When all is done I plan to cover the two additional rivets with some type of filler prior to painting. If it comes out right, nobody will be able to see the mistake, and I can sleep at night knowing its secure and didn't cost me another $100+ bucks!

Thanks all!

[bullojm1]

Peter,

Your fix looks great! Between JB weld and two extra rivets, you should be more than covered.

My recommendation is if you drink enough beers during your build, you won't even remember this "oops" exists.

[captain_john]

Peter, forget about trying to make it look like it never happened.

It is a scar from a previous era. Someday you will look back and remember it and laugh! Besides, it will be repaired in a completely airworthy fashion.

Words to live by:

It isn't about your mistakes; it is how you fix them!

Mike is right, drink on! Ummmm I mean build on!

I will take that bee you owe me at OSH this year!

CJ

[plbarrett2004]

CJ. Deal.

Drinking beer, unlike dimpling, is a skill I've mastered!

[captain_john]

Peter, tell me that you don't drink swill like Mikey.

I am sipping on a Long Trail double bag right now out of Vermont. It is perfect for washing down fiberglass dust!

Hahaha I was sanding my cowling tonight and making it look purdy!

Think you will go to OSH this year?

CJ

[plbarrett2004]

I've never been to oshkosh... But, yeah me and a buddy are planning to go. Hitchhike if necessary since neither of us own airplanes that fly.

Home brewing is one of my other hobbies, but its been awhile since I brewed.

[captain_john]

Cool!

Let's meet up out there!

CJ

[plbarrett2004]

Sounds good!