FlushRivetingTips(doc).docVIP

Flush Riveting Tips Sport Aviation - 4/87 By Tony Bingelis Flush rivets are used, primarily, on external metal surfaces where good appearance and the elimination of unnecessary aerodynamic drag are important. The sleek smoothness of flush riveted skins is considered to be an essential factor in obtaining the maximum performance expected of high performance aircraft. Unfortunately, since flush riveting is an expensive process, most manufacturers of general aviation aircraft have long limited the use of flush rivets to as few components as possible. This is understandable for the extra labor costs could outweigh, by far, the slight performance gain realized from the extensive use of flush riveting. While labor costs arent ordinarily a matter of concern in the construction of a homebuilt, the extra work could be. However, extra work for a good purpose doesnt seem to deter most builders as they are more apt to be freer with their time than with their money. Still, it is well for the first time builder to be aware that extra, time consuming, preparatory steps will be required if he elects to go all the way with flush riveting. As in the installation of conventional protruding head rivets, flush riveting starts with the drilling of the correct size hole for the rivet selected. The additional work generated by the use of flush rivets stems from the requirement to modify the drilled rivet hole to accept the cone shaped head of the flush rivet. This generally means that the drilled rivet hole will have to be either machine countersunk, or compression dimpled to provide the proper nest for the rivet head. But, before we get into countersinking and dimpling procedures, a few important comments regarding the drilling of rivet holes may be useful. Notes About Rivet HolesThere are two ways to make rivet holes. Drill them or punch them out with a tool . . . like the Whitney punch. The Whitney punch is a small hand held lever type punch with interchangeable dies. It can accuratel