Smileys on Horizontal Stab Front Spar:
Rivet gun slipped when riveting the front spar reinforcement bar to the spar. This is deemed no harm to the structural. See detail here.R-710 Short Edge Margin Issue:
Edge margin E/D is about 1.7, less than the ideal edge margin of 2D. This short edge margin is analyzed using FAA FAR25.397c pilot limit load for static ans fatigue analysis, and positive strength margins remain. No part replacement is needed. Stress analysis detail is here. To get an idea of service history of this part, I talked with Ken of Van's Aircraft about this part. He mentioned there are probably a lots of RVs are built with similar less-than-ideal edge margin in this part, but he never heard of any problem on this part. Also, he mentioned very few RVs will see 3000 flight hours (that's 30 years of flying with average 100hr/yr for non-professional pilots). We just can't live long enough to see a fatigue related problem. This just confirms that fatigue is not going to be a problem. I will build on.
Short Edge Margin on Elevator Trim Tab Horn (Build Time: 6-13-2011)
Added another rivet to beef up the joint.
Gap between Left Elevator Leading Edge (Build Time: 6-14-2011)
The pop rivets on the leading edge were drilled out, the leading edge sheet bend was treaked to eliminate the gap. Re-riveted the LE. (work done 6-15-2011)
Used MS-42, -43, -44 to rivet main rib flange to spar web (Build Time: 10-24-2011)
This is a common practice among other builders due to poor accessibility to use solid rivets. Also, the MS-42 rivets are very strong structure rivets.MK-319-BS rivets used on Right Flap Inboard Ribs (Build Log Date: 12-13-2011)
Analysis showed it will ok to use MK-319-BS rivets. Analysis is here. Reference for flap load calculation is here.
Ding on the spar flange due to slipped bucking (Build Log Date: 12-30-2011)
Over countersunk on center bulkhead (Build log: 04-21-2012)
Not a critical area, the hole is not close to the bottom flange, only used to attaching wiring bracket. JB weld is used to fill the gap. Build on.
Short edge margin for a bolt in fore-aft direction (Build log: 05-17-2012): #30 rivet hole enlarged due to misalignment, enlarged hole to accept bolt. This causes a short edge margin problem. So I added a splice with 3 470AD4 rivets, and the bolt will go through the splice. The splice will maitain enough edge margin. This should restore the strength of the original design.
Doubler and shim on F711 bulkhead (Build log: 6-11-2012)
Short Edge Margin on F719 stiffeners (Build Log: 08-19-2012)
Strap is used to repair, Vans said this repair is adequate to address the short edge distance.