Elongation of VS rear spar M4 and 3.3mm rivet holes
Due to mismatch between VS-CHL-001 and VS-ANG-001 due to folding tolerances in the former, it was necessary to elongate holes in order for M4 bolts to pass through with clearance, as well as the 3.2mm rivets. The match between VS-ANG-001 and VS-ANG-003 holes was very good. In the event, the M4 holes were elongated sufficiently to allow the M4 bolts to pass without snagging. This was done before the structure was riveted together.
There was also a need to elongate the 3.2mm rivet holes. Match drilling was fond not to work as the thinner VS-CHL-001 holes would be dragged to follow the positions of the thicker VS-ANG-001 and sometimes VS-ANG-003 hole positions. This is not what is wanted as the skin should be referenced to the VS-ANG-001 hole positions. These holes should also remain lined up with the remaining holes in the upper part of this channel. This problem was overcome by using a needle file to elongate the thicker VS-ANG-001 and 003 holes, leaving the VS-CHL-001 holes unaffected.
For the middle part of VS-CHL-001 where it is backed by just VS-ANG-001 the elongation if pretty small (<0.4mm), 3.2mm rivets can probably be used, as their tails will expand. However for the lower part where VS-ANG-003 is present, above the rivnut holes, it is planned to match drill these to create clean round holes for 4mm rivets. This has been ok-ed by TAF. I might make all the middle holes 4mm as well, this is also ok
This post is from Adam Dickson