Right Wing Frame is Riveted.

In the first picture below you can see the detail of the spacers used with some of the ribs.  The main spar is made up of layers of material and at different places it is different thicknesses.  Since the ribs are all the same size spacers are added as needed so they all line up perfectly. This rib has two spacers, a thick and a thin one to compensate for the center web and the aft web, which don’t run this far out on the spar.

The second picture shows all of the frames completed for the day.  However at this point I had problems with three rivets that I had to replace.

These two pictures show a temporary/permanent fix. What happened was, two rivets did not sit flat against the spar. The rivets were very hard to access here with the thickening of the spar cap, the gussets and the narrower spacing of these three ribs.  I tried to drill out the first one but enlarged the hole.  I went to drill out the second one and got my ribs crossed up and drilled out the wrong rivet!  Worse the drill bit broke in the hole and that hole also ended up enlarged.  I drilled out the other bad rivet with no problem.

I wanted the same solution for all three.  Because of the enlarged holes I could not use the blind rivets.  I have larger diameter blind rivets for just such a problem but they are a little too short for the thickness here.  I also have bucked rivets that would be just the right length, however I think they would be really hard to buck now that the ribs are in place.

I also have bolts that are the same diameter at the bucked rivets.  I decided to drill out the holes to the size of the bolts and bucked rivets and put the bolts in.  If I can figure out how to buck the rivets I will replace the bolts, otherwise the bolts stay.