10-25-2011:
Finished riveting the leading edge ribs to the spar, I used MSP-42 for the other four rivets on the 3rd rib from outboard.
Tapped the tied down using 3/8-16 tap set, it looks good.
Then, a big mistake is made. I tried to fit the tank with the leading. After reajust the wing support in the middle, I got it on good. While looking the fit, I thought the dimple for the #8 screws attaching the fuel tank to the spar were too big, thinking I might used a wrong dimple set. I don't know why I did this, I went ahead and flattened the dimple, and dimpled them using a smaller dimple set (which is 5/32 dimple set accidentally put in the place where I normally have #8 dimple set as I find out later). Put the fuel tank on, the screw stood proud, then I started questioning again, until I found the dimple size was right at the beginning. I was so mad at myself. I know the sheet metal can be flattened and re-dimpled once, but no more. I can't re-dimple it to #8 size because crack will be all over the hole edges. I am doomed. Called Van's support, Ken, and told him the stupidest mistake I made, hoping I can just use #8 screw on a 5/32 dimples. But the answer is negative because the joint won't get its full strength. I almost wanted to cry. I don't mind to build other stuff twice, but not the tank. Ken said he would just go ahead build another tank from scratch, it will cost $400 bulks for the part and one week for the labor (I spent three week to build my tank, maybe the second one will be quicker), but you don't need worry about it later. OK, I will bite the bullet and build another one. I wish I never worked on the airplane today.
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