How NOT to Build a Sonex Elevator

When I started out, this was going to be a How-To video describing my tested method of building a Sonex Aircraft elevator.
I almost got it right, too. Apart from one annoying rivet. Then a second. And then a third.
Learn from my experience, both good and bad.

[@kaethel44]

Paul Dye from KitPlanes magazine does a video on pulled rivets kzbin.info/www/bejne/pnS7g6Sva5Zjl9U. It has been awhile since I watched this, but from what I remember you can use a larger rivet as long as you still have the correct edge distance for the new rivet. I think he also mentions a special rivet with a larger body but smaller head so it does not look out of place.

[@dan_der_flieger]

That's a great video. Thanks for the link!!

[@SkunksWorks]

Oh, the memories flooding back! :) One of the best pieces of advise I ever given to me was, "Remember, you are building an airplane, not a Grande Piano.". Unless you are going for a "Grand Champion Award" at Oshkosh, not everything needs to be visually perfect! Anyone that notices the 5/32 Rivet (as I am sure will be the answer) and says anything negative about it, conforms to one or both of two rules: 1. Has never built an airplane 2. Should not be allowed any closer that 50 feet from your aircraft! Keep them coming Dan!

[@dan_der_flieger]

Nope, not a grande piano ... but it does use the hinges from one. :) I think that's great advice. This is my first go at this and I really need to learn to be OK with less than perfection. There's a good group for Sonex builders over on Facebook and pretty much everyone said that it's almost guaranteed that Sonex will say to just use a 5/32" rivet. I've already ordered a handful of standard 5/32" and a couple of slightly enlarged ones, just in case I need a little more material. In case anyone else ever reads this comment, here are the links to what I purchased to replace the CCP-42 (e.g. the 1/8" SS rivet that came with the kit): www.aircraftspruce.com/catalog/pnpages/CR3213-5-2.php www.aircraftspruce.com/catalog/pnpages/CR3243-5-2.php Anyway, thanks as always for the encouragement!

[@ZIX1231]

Aircraft Spruce sells a great rivet removal tool....

[@dan_der_flieger]

I've considered buying one. Which do you recommend?

[@ZIX1231]

@@dan_der_flieger The one I bought is Part#12-03368 MFR Model #1341S. It’s $82….but it’s been worth it. I’ve had that exact problem where a mandrel remains proud, I drill it out and then the mandrel remains proud again!!! Someone much smarter than me might know why, but I can’t figure it out!! I just filed it down, then used a center punch to push it down into the rivet-worked well and looks fine, plus you don’t deform the hole trying to drill it out again! Love your hinge pilot drilling tool/ruler!!!! I would also suggest having the other half of a hinge (in addition to the pin) attached when you drill the hinge to a control surface-keeps it even straighter than just the pin. Best of luck with the Sonex and keep in touch!!

[@dan_der_flieger]

@@ZIX1231 I did a quick search on aircraft spruce's website and saw that one. I cringed a little when I saw the price, but that's definitely less than ordering new parts from Sonex. Good tip on using the other half of the hinge. I'll give it a try next time. I can't take credit for the piano hinge drill template. I saw it on a video on the Sonex website. It works really well!