Build log documenting construction of my Van's RV-10 airplane.
Started RV-10 on June 29 2022.
Builder #42638
Cleaveland Phone Stand Practice Project
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I put together a phone/pad stand practice project received from Cleaveland Aircraft Tool when I ordered their RV-10 tool kit.
Starting pieces
All edges deburred and corners rounded
All holes drilled, match drilled and deburred
All holes dimpled using DRDT-2
The last steps involved setting the rivets. The instructions recommended attempting to use a bucking bar and rivet gun for some of the rivets, but based on my previous experiences bucking rivets in small parts (hard to keep parts from moving around), I decided to stick to back riveting and squeezing which worked perfectly.
These rivets were all back riveted
The bottom angle rivets were squeezed...
... as were the two rivets by which the back angle piece is attached
Finished kit
Overall, I was very happy with how this practice kit turned out. The only issue I had was slightly overbending the center edges using the edge forming tool, including making a mark in the aluminum sheet when starting an edge bend that was way too tight.
The instructions provided by Cleaveland for this practice kit are very detailed and clearly explained, and definitely benefit folks who are attempting sheet metal work for the first time.
Lessons Learned
When using the edge forming tool, don't clamp the rollers too tightly against the aluminum sheet, otherwise it will be hard to pull the tool along the edge and will likely indent the aluminum surface when starting to pull. Recommended clamping amount is rollers just touching surface + additional 1/8 turn to tighten (see this Cleaveland Video for reference)
Make sure to hold the rivet gun perpendicular to the aluminum sheet being riveted. I noticed some of my rivet shop heads were slightly angled on the top. Use the rivet gun reflection in the aluminum to aid in lining up the rivet gun, by aligning the rivet gun with its reflection.
