Well, I tried some powder coating. The experiment was a qualified success. I was able to get reasonable and smooth coats on some pieces. I think that I will be able to use this process for visible pieces in the fuselage and cockpit. Here’s my first test on a piece of scrap. This is the matte black powder. My coverage wasn’t quite perfect, but it was clear that the electrostatic attraction thing really works. The lighting in my booth wasn’t the best, which I think was a bigger problem.
Then I tried the W-00018 backing plates. The coverage was again a little thin. I think that I can make it better (or if I used a second coat). The powder coat ground was clipped to the crossbar and I was using our old toaster over as a curing oven.
In any case, I ended up giving them a light coat for matte black Rustoleum to make them match the lighting bay color.
I also sprayed the landing light brackets and the inspection hatch doubler while I was at it. Then I was finally ready to tackle all the nutplates called out on page 17-04!
For the backing plates, light brackets, and hatch doublers, I used NAS1097 rivets with the small head and 3/32″ body. These are not structural, and only keep the nutplates from rotating, so the very thin countersink is not a problem. This is much easier than dimpling the nutplates themselves and it keeps from wildly distorting the aluminum pieces with so many dimples so close together. I bolted my squeezer to my work table so that I could concentrate on holding the parts steady.
The splice plates had 18 nutplates each!
I reassembled the left leading edge. It was a little tougher to get everything to fit with the skins dimpled. I had to use a punch pin to align one of the top holes and then cleco away.
I didn’t get much else done (heading out for an evening date with the wife.. gotta keep her happy after spending all day with my aluminum girlfriend!). I did manage to get the access hatch done. I think I like the flat black paint on the doubler instead of the primer. I’ll likely do the other access hatches this way.
Next up, I’ll prep and prime the ribs for the right side leading edge (a bit less work since there is no access hatch nor stall warning vane). Also have to do all the dimpling for the right skin and J-stiffener. After that, it will be a flurry of riveting.