Skin blemishes/making a new skin

[Jesse Jenks]

I spent over nine hours today drilling, cutting, filing, deburring, and
Scotchbrighting. My arms are exhausted, but I now have a perfect new skin. I
used a spacer between the original skin and the blank and an egg cup
bushing as discussed. I used card stock about .030 thick which seems about
right. The majority of the holes stayed centered, and a few showed signs of
wandering in the original skin. The moment of truth will come tomorrow when
I cleco the new skin in place on the wing, but at this point it's going on
one way or another. After this ordeal I will remove the plastic from my
skins with a toothpick if that's what it takes to not dent them.
Jesse





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[Jeff McMurrer]

Hi Jesse,

Sounds like you had quite the ordeal. I

[Jesse Jenks]

Thanks Jeff,
I may end up using some 5/32 rivets before this is over. I do realize that I
will have to accept some imperfections during the build process, but I want
to do my best within reason. Once it is born out into the real world I'm
sure there will be plenty of dings and scratches, but I want to start out
with nice airplane.
Where do you get those 5/32 Avex rivets? I think I saw them in the ACS
catalog, but they are probably $1.00 each or something like that.
Jesse


[quote]From: Jeff McMurrer <westcoastkitplanes@shaw.ca>
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: Re: Skin blemishes/making a new skin
Date: Sun, 04 Sep 2005 08:42:03 -0700

Hi Jesse,

Sounds like you had quite the ordeal. I

[Dale Fultz]

Call MAM they will sell them to you.
----- Original Message -----
From: "Jesse Jenks" <jessejenks@hotmail.com>
To: <rebel-builders@dcsol.com>
Sent: Sunday, September 04, 2005 12:07 PM
Subject: Re: Skin blemishes/making a new skin

Thanks Jeff,
I may end up using some 5/32 rivets before this is over. I do realize that
I
will have to accept some imperfections during the build process, but I
want
to do my best within reason. Once it is born out into the real world I'm
sure there will be plenty of dings and scratches, but I want to start out
with nice airplane.
Where do you get those 5/32 Avex rivets? I think I saw them in the ACS
catalog, but they are probably $1.00 each or something like that.
Jesse

From: Jeff McMurrer <westcoastkitplanes@shaw.ca>
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: Re: Skin blemishes/making a new skin
Date: Sun, 04 Sep 2005 08:42:03 -0700

Hi Jesse,

Sounds like you had quite the ordeal. I've had to replace a few skin
s here and there over the build project time. For reasons I won't sa
y.

If you do find that some of your holes do not line up perfect or you have
too much load on the skins/rib because of forcing the holes to align.
Just remember, you can upsize the hole to 5/32 and nobody would know b
ut you.

Everything is repairable and fixable. And there will be more dents,
creases and imperfections before you're done. One of those things yo
u will have to get used to. Unless you're planning on keeping the pl
ane under a glass case, as was stated earlier by someone with experienc
e.

Keep up the spirits; it's all worth it in the end.

Jeff




----- Original Message -----
From: Jesse Jenks <jessejenks@hotmail.com>
Date: Saturday, September 3, 2005 5:54 pm
Subject: Skin blemishes/making a new skin

I spent over nine hours today drilling, cutting, filing,

deburring, and

Scotchbrighting. My arms are exhausted, but I now have a perfect

new skin. I

used a spacer between the original skin and the blank and an egg

cup

bushing as discussed. I used card stock about .030 thick which

seems about

right. The majority of the holes stayed centered, and a few

showed signs of

wandering in the original skin. The moment of truth will come

tomorrow when

I cleco the new skin in place on the wing, but at this point it's

going on

one way or another. After this ordeal I will remove the plastic

from my

skins with a toothpick if that's what it takes to not dent them.
Jesse

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[Jesse Jenks]

I have the new skin clecod on. The hole alignment wasn't perfect, but not
bad either. I cheated on a handful of holes and just ran a #30 drill
through. I'm pretty happy with it now though. Tomorrow it gets riveted.
Jesse





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[jtpackard]

Jesse:
I think the current catalog from ACS only shows countersink 5/32 Avex
rivets, so I'm not sure they carry the 'dome' head style. I ordered some
from Wicks a couple of weeks ago. Their catalog shows them all at $.10ea,
and when I asked about a quantity discount they agreed their catalog was
incorrect and the price is $0.06 -$0.10 ea depending on quantity. I believe
this is less then the MAM price.

Regards,
Tom Packard
SR 043

----- Original Message -----
From: "Jesse Jenks" <jessejenks@hotmail.com>
To: <rebel-builders@dcsol.com>
Sent: Sunday, September 04, 2005 11:07 AM
Subject: Re: Skin blemishes/making a new skin

Thanks Jeff,
I may end up using some 5/32 rivets before this is over. I do realize that

I

will have to accept some imperfections during the build process, but I

want

to do my best within reason. Once it is born out into the real world I'm
sure there will be plenty of dings and scratches, but I want to start out
with nice airplane.
Where do you get those 5/32 Avex rivets? I think I saw them in the ACS
catalog, but they are probably $1.00 each or something like that.
Jesse

From: Jeff McMurrer <westcoastkitplanes@shaw.ca>
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: Re: Skin blemishes/making a new skin
Date: Sun, 04 Sep 2005 08:42:03 -0700

Hi Jesse,

Sounds like you had quite the ordeal. I've had to replace a few skin
s here and there over the build project time. For reasons I won't sa
y.

If you do find that some of your holes do not line up perfect or you have
too much load on the skins/rib because of forcing the holes to align.
Just remember, you can upsize the hole to 5/32 and nobody would know b
ut you.

Everything is repairable and fixable. And there will be more dents,
creases and imperfections before you're done. One of those things yo
u will have to get used to. Unless you're planning on keeping the pl
ane under a glass case, as was stated earlier by someone with experienc
e.

Keep up the spirits; it's all worth it in the end.

Jeff




----- Original Message -----
From: Jesse Jenks <jessejenks@hotmail.com>
Date: Saturday, September 3, 2005 5:54 pm
Subject: Skin blemishes/making a new skin

I spent over nine hours today drilling, cutting, filing,

deburring, and

Scotchbrighting. My arms are exhausted, but I now have a perfect

new skin. I

used a spacer between the original skin and the blank and an egg

cup

bushing as discussed. I used card stock about .030 thick which

seems about

right. The majority of the holes stayed centered, and a few

showed signs of

wandering in the original skin. The moment of truth will come

tomorrow when

I cleco the new skin in place on the wing, but at this point it's

going on

one way or another. After this ordeal I will remove the plastic

from my

skins with a toothpick if that's what it takes to not dent them.
Jesse

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[Jesse Jenks]

Thanks Tom,
I got the new skin on without oversizing any holes, but I will remember that
for the future.
Jess

From: <jtpackard@usfamily.net>
Reply-To: <rebel-builders@dcsol.com>
To: <rebel-builders@dcsol.com>
Subject: Re: Skin blemishes/making a new skin
Date: Tue, 6 Sep 2005 08:56:18 -0500

Jesse:
I think the current catalog from ACS only shows countersink 5/32 Avex
rivets, so I'm not sure they carry the 'dome' head style. I ordered some
from Wicks a couple of weeks ago. Their catalog shows them all at $.10ea,
and when I asked about a quantity discount they agreed their catalog was
incorrect and the price is $0.06 -$0.10 ea depending on quantity. I
believe
this is less then the MAM price.

Regards,
Tom Packard
SR 043

----- Original Message -----
From: "Jesse Jenks" <jessejenks@hotmail.com>
To: <rebel-builders@dcsol.com>
Sent: Sunday, September 04, 2005 11:07 AM
Subject: Re: Skin blemishes/making a new skin

Thanks Jeff,
I may end up using some 5/32 rivets before this is over. I do realize

that
I

will have to accept some imperfections during the build process, but I

want

to do my best within reason. Once it is born out into the real world I'm
sure there will be plenty of dings and scratches, but I want to start

out

with nice airplane.
Where do you get those 5/32 Avex rivets? I think I saw them in the ACS
catalog, but they are probably $1.00 each or something like that.
Jesse

From: Jeff McMurrer <westcoastkitplanes@shaw.ca>
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: Re: Skin blemishes/making a new skin
Date: Sun, 04 Sep 2005 08:42:03 -0700

Hi Jesse,

Sounds like you had quite the ordeal. I've had to replace a few skin
s here and there over the build project time. For reasons I won't sa
y.

If you do find that some of your holes do not line up perfect or you

have

too much load on the skins/rib because of forcing the holes to align.
Just remember, you can upsize the hole to 5/32 and nobody would know

b

ut you.

Everything is repairable and fixable. And there will be more dents,
creases and imperfections before you're done. One of those things yo
u will have to get used to. Unless you're planning on keeping the pl
ane under a glass case, as was stated earlier by someone with experienc
e.

Keep up the spirits; it's all worth it in the end.

Jeff




----- Original Message -----
From: Jesse Jenks <jessejenks@hotmail.com>
Date: Saturday, September 3, 2005 5:54 pm
Subject: Skin blemishes/making a new skin







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