Second remanufacture of RF-ANG-003 and complications

I found that the outer arch skin holes did not match well with the remanufactured RF-ANG-003. Its vertical flange holes mismatched the outer arch skin holes both vertically and laterally by about 1.5mm. These holes were based on the originally supplied part. So I remanufactured the RF-ANG-003 without these holes, and for good measure remanufactured RF-ANG-004 which were otherwise ok, but I also wanted to correct a hole mismatch on the flat surface of the latter with one of the top rail angle CF-ANG-010 holes.

Addendum: In the first remanufacture of the RF-ANG-003 I had also dimpled two rivet connections to RF-ANG-004 to take upwards-facing rivets. This would not work as there is a trapped 4mm rivet head attaching the latter to the longeron 301. The sequence would not work. But I had already dimpled the RF-ANG-004 - cannot be undone - so I had to remake these anyway.

I left out the vertical flange holes of the RF-ANG-004 for now, but the positions of the supplied part were good so it will likely serve as a reliable template.

As for taking advantage of the hole in the CF-ANG-010, I noted that when this was done, the tail would interfere with the longeron 301. I did not want to cut a notch in this, so the options were to use a countersunk rivet from underneath passing 1) though just RF-ANG-003 and 4 as with the first remanufactued RF-ANG-003 and dimpling as before and ignoring the hole in CF-ANG-010 or 2) countersinking the CF-ANG-010 hole and passing though all three layers without dimpling of course.

I chose to countersink but as this hole was so damn close to the edge of CF-ANG-010 with the countersinking reaching all the way to the edge of this part I realised I should have just did what I did before as I was creating a location of stress concentration.

What a fuck-up!

I took bold action and files this hole and countersinking out completely, making the radius large enough reduce the chance of stress concentration. The total amount of material removed from the horizontal flange of the CF-ANG-010 was about 2.5mm in all.

As a precaution I created a doubler for this flange from 1.6mm sheet to insert inside the longeron 301 to (more than) compensate for any loss of material.

Addendum: For the same reason as above - the trapped 4mm rivet head - I also need to make all rivets attaching RF-ANG-003 and 4 together downwards-facing. One of these will not connect with the CF-ANG-010 hole which I have notched out. Instead I am hoping the tail will be compact enough when set to not interfere with the longeron 301. A bit back to where I started - I evidently did not think this through enough. I should have just ignored the CF-ANG-010 hole completely. But perhaps there is value in eliminating a hole so close to the edge (basically a stress riser) and adding the additional doubler plate. Hmm…