Well folks, I've made a ton of progress since my last post. I have the cabin sides ready for solid riveting. I'm also ready to start match drilling the wing spar pieces. I've made about 75% of the parts in the plane. About 3 weeks ago, I broke my bending brake trying to bend some longer .063". The pop rivets holding the piano hinge pulled out. So, I thought I'd use the opportunity to practice my solid riveting by repairing the brake with bucked rivets. What a disaster. I simply CANNOT get the hang of solid riveting with my 3X "red box" gun from Aircraft Spruce. I have my compressor pressure set at about 90 PSI, and I've played with the regulator on the gun a bunch (high, low, medium, etc.), but nothing makes any difference. Whenever I try to set a rivet, the gun beats the hell out of the universal head of the rivet, and the shop head never forms. I can get the rivet to swell slightly in the hole, but no matter how much I try to form the rivet, the shop head just won't form. In addition, the universal head of the rivets get smileys, the surrounding material gets all damaged and nothing will form properly. I can even pop the rivets out with a punch afterward. I'm using modest/heavy pressure on the gun side of the rivet, and modest pressire with the bucking bar. I keep the universal head firmly against the material. I have the correct rivet set in the gun. I'm setting AN470AD-5-12 rivets trimmed so that 1.5X of the rivet is protruding from the hole. All the online (EAA Hints for Homebuilders, YouTube, etc.) videos make this look easy, but something is way wrong with my technique or my gun or my pressure setup. Any guidance/thoughts? Really frustrated since my brake is also down until I figure this out. It feels like the rivets are already shop-hardened as soon as I pull the trigger!

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Comment by Clint L Gosch on March 9, 2016 at 7:24pm

Hi Greg,  Have you taken a look at the c-frame riveting method?

 http://www.eaavideo.org/video.aspx?v=1803209366

By your description, it may be a pressure issue but its hard to tell without watching your technique.  I made many practice pieces to perfect the bucking bar process, It seemed I could get quite a few rivets set and then I would screw up one.  I bought a c-frame and had great luck, my spars turned out flawless.  The c-frame holds everthing in perfect alignment so all you need to focus on is pulling the trigger. I'm sure the bucking bar method can be made to work, but I just could not quite develop the skill to get good results.  Hope this helps! Good luck!

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