12-28-2011: 4 hrs
I also enlarged the hole on the skin for the tie down eye bolt to 1/2", and cut a piece of the plastic tube (1/2" OD, 1/4" ID) for spacer between the eye bolt and the tie down bracket.
The rib to spar rivets that are underneath the fuel tank are set, getting ready to install the fuel tank soon.
Started working on the big push rod. I cut one rod about 2/32" short of the required 65 25/32" length, so I moved the rod end out a little. This will results an edge margin (E/D) less than 2. The final E/D is about 1.5 for the rod end. With rod end thickness of 0.05", and assuming shear allowable of the material is 20ksi, with D = 0.125", the shear tear out load is about 250 lbs. There are total 6 rivets, so the total load for tear out is about 1500 lbs. The buckling load of the push rod is about 300 lbs. So, the E/D = 1.5 edge margin is OK.
Previous wire was not bent correctly (missing the second bent that goes through the bushing at the bottom of the unit). Here it the correct one
Sealed the baffle to skin rivet shop heads
Access plate and fuel sender unit are installed
I used a plastic pipe as the spacer for the tie down eyebolt
Hole on the bottom skin is enlarged to 1/2" dia.
The spacer fits the skin pretty well
Then I riveted the flush head rivet that will be blocked by the tank skin after tank instl.
The shop heads of the these flush rivets look good
I started working on the big push rod, I used a piece of paper with rivet location mark to wrap around the rod and marked the hole locations for drilling, it worked well
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