The procedure I use to remove the AD-6 rivets from the spar for the upgrade is to first drill through the head with a 5/32 drill, shear the head off with a chisel, and then drill about 1/4" into the rivet with a 1/8" drill. I then use a 1/8" punch with an air hammer and push the rivet out.

The last thing I do is inspect the rivet to make sure that the drilling operation didn't go beyond the circumference of the rivet resulting in an enlarged hole in the spar. I'm happy to report that I've removed all the required rivets in one spar without any mishaps!

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Comment by Jerold Ebke on November 27, 2010 at 10:20am
Dale, We met at Mexico near Gus and his 750. Have you learned any more info specific to our 650's concerning installation of UL engines? I have not tried to call and talk to Gus specifically concerning installation. Have you?
I am concerned about fuel pump on inside of cockpit as potential for pressurized fuel leak. William Wynn writes of in cockpit leak and fire he endured and his admonition to never put pump or any pressurized fuel line inside cockpit. Any thoughts on this idea? Seems like lots space with long motor mount to create cooled enclosure on front of firewall. Maybe could run return line on belly and "Y" off to tanks through bottom of wing. Jerry
Comment by Dan Dempsey on December 6, 2009 at 6:04pm
When drilling the skins on my first wing I screwed up one of my spar caps and opted to replace it, and in doing so found the rivets very difficult to drive out. I solved the problem by making a little jack. This worked like a charm.
http://daniel.dempseyfamily.us/zodiac/wings/BigGoof/rivetRemovalToo...
Comment by Dale Medendorp on December 5, 2009 at 4:36pm
Dave,
I forgot to mention the clamping. You're absolutely right needing to do that.
Comment by Timothy R Mix on December 5, 2009 at 10:35am
Backing up on the edge of the shop head with a bucking bar will help too when removing the rivets. (less bounce)
Comment by David Gallagher on December 4, 2009 at 6:05pm
Dale, that worked for me too. I also found out the the sandwich of spar material needs to be clamped tightly together for the rivet to come out. Otherwise, the spreading of spar layers served to lock the rivet in place.

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