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Here are
some of the things you are going to learn
This page contains
instructions for building the Panel from Van's that will
be most of the skills required on the sheet metal part
of any Van's aircraft.
Building Van's Practice Panel
Make the first cut 1/8" from line
then go back and trim to the line
A good way to smooth the part is to
use a 3M Wheel
Part edges are smooth after
deburring. Use a Sharpie and mark the part number
Match drill the stiffeners to
skin
Deburr the holes in the skin and
stiffeners that you just drilled
If you are going to prime now prime
the inside skin and stiffeners. There are quite a few
different ideas on priming and you will want to read
Van's recommendations in the manual. The prep for the
skins is to first Scotch Brite the metal to scuff it and
then clean it. For the class project we will use a self
etching primer. Other types of primers will be discussed
and you can make your own decision.
Dimple the skin holes for the
stiffener using the "C" Frame
Another method to dimple the
stiffeners is to put the dies in a squeezer and put the
squeezer in a vise and "Squeeze the dimple. This method
work anywhere the squeezer will allow you to reach the
holes. You can also use the "C" Frame to do them.
If you want to keep the blue
protective cover on as long as possible, use a soldering
iron to score the area to be riveted and the protective
blue will peel off along the line.
Back rivet the Stiffeners
Remove tape from rivets and check to
see if all the rivets are flush.
Back drilling rib to spar using holes
as a guide and using a long drill
After disassembling the Rib/Spar and
deburring reassemble and drill to reinforcement plates
The Plans have the rivet callouts on
them. Here you see 10 AN470AD4-4 Rivets will be
used to rivet the reinforcement plates on.
Riveting the reinforcement plates
Drilling the skin to the ribs
Drilling skin to the spar using the
holes in the skin as a guide.
Use temple to establish angle for
drilling the trailing edge
Used the "C" Frame with dimple Dies
to do holes in skin.
You can construct the special dimple
bar shown in plans for the hard to get rib holes, or I
prefer to use the vise grip dimple dies that are
included in a lot of the RV builders kits available thru
Avery or Cleveland. They work well in tight areas and I
consider them one of my required tools.
To do the Spar Flange begin with the
dimpling. Here I used my squeeze handles with dimple
dies.
Finish by countersinking with micro
stop countersink cutting deep enough for rivet
Here you can see the rivet flush with
the top of the flange
Counter sink the trailing edge. This
needs to be countersunk on both sides
Picture of holding fixture holding
the part in place after the bottom skin is cleco on.
Ready to rivet
Cleco on the bottom skin using the
holding fixture built from the plans
Rivet the skin to the front spar
Squeeze the skin to rib rivets
Using special bucking bar to buck the
last rivet on the rib.
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