Double-click on photos to enlarge.
This photo shows good detail of the "factory" head, and "shop" head on a protruding head rivet.
Rivet tape ... very helpful stuff.
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"Factory" head on rivet should go on the side of the thinner material unless specified differently on drawings .
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Builder Log for ...
Sonex 963
Building a Dream!
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Page 11
Photo Courtesy of Sonex Aircraft, LLC
August 11, 2007 ...  I finally started setting  rivets today!  I found it to be exhilarating work, after spending so many hours fabricating brackets and updrilling spar parts. I am using the "ooga-booga" (caveman) bolt and hammer method of setting my rivets, and seem to be getting excellent results. I quickly abandoned the riveting frame (See Wings, Page 9 of this Website). I found that once I had the bucking bar perfectly perpendicular to the spar, holding the bolt straight, and getting a good "shop head" was pretty easy. Three or four good smacks with a 4 pound sledge hammer did the job. I am starting with the flush rivets on the inboard end and working outward.
August 15,  2007 ...  Sonex builder (625), Christopher Byrd from Olympia, Washington stopped by to take a look at the progress on my wing spar. While he was here, he wanted to try setting a few flush rivets. He did a great job, and as always, it was great to share builder tips.
August 20 & 21, 2007 ...  During these last two days I took whatever free time I could muster to set as many rivets as possible. I made good progress but still have about 26 more rivets to go. I am very happy with the way the rivets turned out, although I have seven that are canted or not to my liking.  I am including photos of "the good, the bad, and the ugly." Of course, the "bad and the uglies" will be drilled out and replaced. It is great to see the spar come together!
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There's "ugly" ... then there's REALLY ugly!
September 4,  2007 ...  'Just turned one year since I started this project! It's been great fun!  Today, I finished riveting the right wing spar, and started replacing "the bad and the ugly" rivets (along with the "REALLY ugly!")   Hopefully, by seeing some of my mistakes (aka "teaching moments"), if you are a builder, you will be able to save some time and rework.
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Notice the flatter than normal "shop" head (left photo), which is a result of a raised "factory" head (right photo, red arrow). I accidently set the adjacent bolt head on the bucking bar.
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Paint Ideas, Page 1
Paint Ideas, Page 2
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"Why Build?"
"Why a Sonex?"
"Experimental" Aircraft?
Helpful Links
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VS Airframe & Rudder
Rudder & VS Skin
VS Fiberglass Tips
VS Final Assembly
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Drawings & Shop Set-up (1)
More Shop Set-up (2)
Wing Hoist
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Horiz. Stabilizer, Airframe
Elevator Control Horn
Elevator Assembly
Horizontal Stabilizer, Skin
HS Hinge & Tips (1)
Horiz. Stabilizer, Tips
HS Final Assembly
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