2 Oct 05 - Wingtip Foam, Wingtip Nutplates

We're finally going to use the space invader foam that we got from Aircraft Spruce a few weeks ago. Why are we using this? There's a discussion at the bottom (very last paragraph) of this page right here. I had seen this discussed awhile ago on one of the RV lists, and this seems like it might be interesting. Let's give it a shot:

Left wingtip full of foam. This was two whole cans (all we had) - I thought this was going to go farther than that, but these wingtips have a lot of space in them. It takes awhile to cure, so I guess we'll see what happens tomorrow.
After a few minutes of curing. Yeah, no real change. After it gets hard enough to not slosh around in there, we'll put it back onto the wing to make sure it keeps its same shape.

Figuring out how to do these nutplates is something we've been stewing on for awhile. I think the last attempt to do it was such an unmitigated disaster that it didn't even make it on the site, and is now in the realm of suppressed memories, I suppose.

Now, we're trying something a little different: soft rivets, using the back riveting set (what you're wacking the rivet with has to be small enough to fit onto the lip), and turning the air pressure waaaaay down. Also, we're using nutplates that we actually tapped a few days ago so it wouldn't be such a struggle to get the screws in and out. I do not recommend doing this to all the nutplates on your airplane, because the screws will have more of a tendency to become undone with any amount of vibration. In my opinion, for structural parts of a plane (which this isn't), tapping the nutplates is not such a great idea.

First one in progress. Also, as you can see, we're using rivet tape to protect the fiberglass.
This one is all done!
Detail of the nutplate and screw. We're also using NAS390 B6P washers from Aircraft Spruce.

So how did it come out? Pretty well, though because of the riveting set that we used perhaps there's some sanding and filling in of dents and things that needs to be done to generally where it was riveted on. Nothing really bad, though . . . just cosmetic.

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