Follow us on Twitter Follow us on FaceBook Kitplanes Videos Get RSS Feed
 

Shop Talk

August 2017 Issue




The Creative Homebuilder

Simple tools for setting smooth pop rivets.

When setting an aluminum pull (or "pop") rivet, sometimes the hole in the pulling head is a little too large and a "feather" of aluminum is pulled into the hole, leaving a slightly rough surface at the rivet's face. In order to get an absolutely smooth finish, our Creative Homebuilder made a little handle. The hole at the tip is as close to the mandrel diameter as possible, and a little bend to the handle accommodates ergonomics, putting the handle at a convenient angle when pulling a rivet. As the rivet is pulled, no aluminum can be "cold worked" into the original hole in the pop rivet gun, guaranteeing a smooth surface.

Pop rivet "tight fit" pull sleeve.

Side view showing handle-to-rivet interface.

Close up of the whole assembly in a pop rivet gun.

While pop rivet angle adapters are familiar to many, our Creative Homebuilder has been using them for 30+ years and picked up a few tricks along the way. Take a quarter-inch round rod, cut one face square and cut the other face back at an appropriate angle to provide relief from interference with the nose of the riveter. Then drill a rivet-shank size hole in the center of the adapter and paint the adapter a bright color to facilitate recovery of the small piece. Once the paint dries, place the adapter over the rivet and bend the rivet shank until it is square with the angled face. Finish by pulling the rivet. This technique also lessens the "feather" issue mentioned above.

Pop rivet angle adapter is painted red to facilitate recovery when the stem breaks and the gun separates from the skin surface.

Close-up of the pop rivet angle adapter placed in a pop rivet gun and ready to install a rivet. A similar technique is to use a small piece of AEX wedge in place of the beveled round rod.

Download File

Untitled Document Homebuilder's Portal by KITPLANES
Photo by Richard VanderMeulen
I completed Sonex #1072 on August 18, 2014 and made the first flight on August 22, 2014 from Charlie Brown/Fulton County Airport in Atlanta, Georgia. The airplane now has over 150 hours on it and has made several trips from Atlanta to South Florida, the Carolinas, and to Tower, Minnesota which is just south of …
My CubCrafters EX N-96FV was finished July 30, 2016 - last weekend of AirVenture. My 87-year old Dad was the first passenger after my 40-hour fly off. He flew chase in his Cherokee for the maiden flight. It's painted in D-Day colors for my C-130 unit's 70th anniversary. 96th Airlift Squadron Flying Vikings were the …
It started with a visit with the Rutan guru Robert Harris of what was the EZ Hangar in Covington TN, now EZ Jets. I wanted to build a Long Eze but Robert suggested using current information and technology instead of 1977 when the plans came out. From then on, this airplane was not a Long …

Dynon Avionics' latest-generation SkyView integrated avionics called the SkyView HDX has a newly designed bezel and user controls for easier use while flying in turbulence, plus brighter displays and a reworked touch interface. Larry Anglisano takes a product tour of the HDX with Dynon's Michael Schoefield in this video.
At Sun 'n Fun 2016, Dynon continued to push into the world of non-certified avionics with its SkyView SE, a less expensive version of its popular SkyView EFIS system. Paul Bertorelli prepared this video report.
The G5 is a self-contained electronic flight instrument, which can be interfaced with Garmin's G3X/Touch avionics and autopilot for backup and flight instrument redundancy. The GMA245 and remote GMA245R Bluetooth audio panels have advanced entertainment input functions and onscreen programming.
At Sun 'n Fun 2016, Just Aircraft is showing off its new Titan-powered SuperSTOL XL. Harrison Smith took Paul Bertorelli for a half-day demo flight in the new airplane, and here's his video report.
Kit manufacturer Zenith Aircraft Company has released a new 360-degree VR short video to showcase its kit aircraft and to promote the rewarding hobby of kit aircraft building and flying light-sport aircraft.
Whether you are upgrading the audio system in an older LSA or experimental or building a new project, PS Engineering and Garmin have non-certified audio panels equipped with advanced features better suited for smaller cabins.
Video Archive

IMPORTANT CUSTOMER SERVICE NOTICE TO KITPLANES SUBSCRIBERS:


All mailed correspondence, including subscription invoices, renewals, and gift notices, will bear our address:
PO BOX 8535
Big Sandy, TX 75755

Third parties claiming to be selling KITPLANES subscriptions are not legitimate.