OP-51 Sheet Metal Basics

After installing a new blade on my bandsaw, I decided to start on the small practice project included with the empennage kit, called OP-51. It's two 4x5 pieces of aluminum sheet and a 5" aluminum angle, joined together in various ways including countersunk rivets, universal head rivets, and blind rivets. It also includes layout and machining tasks.

It was definitely good practice and I learned a lot about my tools and these techniques. When I was done I filed the project away in my materials drawer in case I want some scrap aluminum to practice on later.

One particular thing of note is that installing a screw into a nut plate for the first time can require a ton of torque. It feels like you're tapping the nut plate. I did one by brute force, then did an internet search after I saw the discoloration that resulted on the screw. Consensus seems to be that a minute amount of Boelube or beeswax helps a lot. I didn't have either, so I tried rubbing a tiny bit of 3-in-1 oil on the screw threads, and that worked well. I did order some Boelube, though.