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Old 05-01-2015, 04:24 AM   #1
Ronboone
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Default Fabricating the spats

We are finished making the template for the spats on our Acroduster Too and have a couple of questions: What type of aluminum is common to use? What is the common method of joining the trailing edge? Any photos?

Ron


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Old 05-01-2015, 06:22 AM   #2
Dave Baxter
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Ron there are all kinds of ways, but here is one from the old Starduster Magazine. .025 2024-T3 Alum and 8-32 Philips screws is the most popular choice. Dave


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Old 05-01-2015, 11:16 AM   #3
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Dave

What issue is that article in .
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Old 05-01-2015, 02:03 PM   #4
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Nice work Dave. Patterns are a PITA.
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Old 05-01-2015, 05:36 PM   #5
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Jerry the Tech Tips Article was in the July 1991 issue of Starduster Magazine. Dave
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Old 05-02-2015, 12:33 PM   #6
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Thanks, Dave.
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Old 05-02-2015, 05:52 PM   #7
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I used 8-32 screws with acorn nuts to give it a bit more finished appearance.
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Old 05-02-2015, 08:34 PM   #8
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Default Fairings

8-32 is overkill. 6-32 is fine.
You can also flush rivet the trailing edge or fold the trailing edge. Make a seam on the inboard side far enough forward of the trailing edge to accommodate 6 32 anchor nuts. Rivet a doubler on the inside aft edge, then anchor nuts and flush screws forward of the seam. The screws thru the trailing edge look ugly no matter what type screws and nuts you use.
Flush riveting the trailing edge, a filler strip at least .050 thick is used. Match drill the three pieces, dimple the outer pieces for 3/32 flush SOFT rivets and countersink the filler strip to accommodate the dimples. Put a nice radius on the trailing edge of the filler strip.
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Old 05-03-2015, 01:17 AM   #9
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As always, thank you Dave for your post.

Jim, good ideas.

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Old 10-30-2017, 11:57 PM   #10
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Waking this thread up instead of making a new one...

I have to make at least one new Spat. Mine are a bit more curvy than Daveís drawing and I like it so will be slightly different but same idea. (Iíll post some pics). My question is what is the best thickness to use? 2024-T3 .025 or .032? I have .032 now and seems a bit heavy but wondering how .025 would hold up? The weight difference is little (but I bet it is some) also whatís the best way to roll the trailing edge? My current ones didnít have that detail and Iíd like them flush not pulled in at every screw.
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Old 10-31-2017, 12:16 AM   #11
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I used .025 Didn't do anything to the trailing edge w/6-32 screws.
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Old 10-31-2017, 04:04 AM   #12
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Does the .025 seem to be holding up? I know you are going for light as you can, but if you had it to do again would you still use .025? Or go thicker?
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Old 10-31-2017, 05:37 AM   #13
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Kris .025 is fine, .032 is overkill and much harder to work with as well as getting them off and on. The .025 has lasted with little problems for over 27 yrs mine cracked around the inside top, by the landing gear bungee arm that required a small patch doubler, and of course unless you routinely kill a runway lights then .032 might be better! Ask me how I know? I also like the polished 6-32 stainless nuts and screws, just me. Dave
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Old 10-31-2017, 05:45 AM   #14
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I don't have nearly the time Dave has but .025 is plenty IMO. If I had it to do again I might try .020? Or go light and take them off?

No, they really make the Dusters........

Jack
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Old 10-31-2017, 05:47 PM   #15
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Thanks guys...Iíll go with 025.


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