Several work sessions; July 30, August 2, 3 and 4, total of 4 hours
July 30: Test fitting the top skin showed a couple of areas where I needed to break the edges a little more. A quick bend with the hand seamer, and then a re-check showed that everything fit nicely.
August 2: I started by riveting at the forward end and worked backwards, per the instructions. It was easy going bucking these rivets until I was unable to reach comfortably. Then I removed all clecos, and taped up some rivets in preparation for back-riveting.
August 3: By carefully rolling the fuse onto the top skin, and climbing onto the bench, I was able to back-rivet up to the first bulk-head. I ran into an issue on the bulkhead, where the rivets didn’t sit down into the holes in a couple of places. The problem was caused by my positioning of the fuse flat on the back riveting plate, instead of at a slight angle. I moved on, riveting the remaining rivets up to the 2nd bulkhead. This was a lot of fiddling around; starting with the fuse on it’s side, I’d insert around half a dozen rivets on each side of the skin. Then I’d position my back riveting plate, then roll the fuse onto it’s top, and secure with some tie down straps rigged up to the ceiling. By tightening and listening the straps I was able to position the side at just the right angle. For the rivets. A quick check to make sure everything looked right, then up onto the bench, crawl into the fuse, set the rivets, then roll to the other side, check positioning, climb back in and rivet the other side. Then release the straps and roll the fuse onto it’s side to check my work and insert the next set of rivets.
But the end result was worthwhile; nice tight skin alignment, and some good looking rivets. I replaced the bulkhead rivets and wrapped up for the night.
August 4: I finished the top skin by bucking the remaining 30 rivets on the aft end of the skin. I contemplated back riveting these, but decided the risk of crawling that far back into the fuse, wasn’t worthwhile. Too much chance of bending something, or losing my balance and crashing everything onto the floor. By reaching in from the access point on the aft bulkhead I was able to easily buck these rivets, and despite not being able to see the rivets, they came out great. I’m really enjoying my new tungsten bucking bar. It’s about 2 inches square, fits nicely in the hand and seems to do a nice job. Using a couple of pieces of foam on the edges makes it very easy to ensure it’s level.
Overall I’m happy with the result, and pleased to be finished with the aft fuse construction. I still need to drill some holes for the VS, but I’m otherwise complete.
