Flush siding -- rivets or steel
Posted: Mon Feb 16, 2009 1:30 pm
Ahoy, Eagles,
My Eagle is entirely flush riveted, with 3/16" x 120 deg rivets, holding 0.080" thick aluminum 5052-H32 alloy. It is the stuff that 'black boxes' are made of, and can be flanged 90 deg without cracking. The skin is not flanged, but a lot of other stuff that you make is, so it is good for all around use. Costs less than 6061-t6, which must have a x2t to a x4t bend radius. I have had NO trouble with denting, and I put it on 'hot', at about 130f, and there is NO wrinkling in the heat.
Sounds perfect, yes???? ---- Not quite!!!! Go and look at any big airplane which is riveted, (especially if it has had a lot of cat shots) and you WILL see the rivets. Perhaps not immediately, but you will eventually. My Eagle Bus does. I'm not troubled by that, and decided way back that spot blasting and sanding flush rivets was a LOT easier than working around protruding rivets. Yah, I really need to do a corrosion job and re-paint on my Eagle soon, but not today.
On an earlier post, there was mention of using steel for siding. The idea has some real merit. Work it hot, MIG weld the edges -- always locating the edges on the tubing structure. When cool, it will be absolutely drum tight, and won’t loosen and buckle in hot weather. Since it will be tight, it does not have to be very thick -- say if you use ~~0.040” stock would weigh like 1/8” thick aluminum. Metal creep does not occur on the materials we use and at the loads and temperatures that we see.
The edges and seams will fill with bondo quite nicely, and with a continuous – non-moving – weld seam, should hold just great.
Details of the welding -- If I were to try it, I’d not try to use immense sheets. If the scheme works, comfortable sizes will do just as well. Say -- from the baggage bay longeron to the window line, and several feet long, starting and ending on a member. Gap the adjoining pieces ~~ ½” so there is comfortable room for your weld. Try a 1” weld every 3” while you keep the sheet hot and tight with clamps and magnets. Temp of ~~130f is OK, any higher, and you can get burns). Then go back and finish the welds -- still hot. I believe that the process would be a good bit quicker than rivets.
By the time that you have done three adjoining panels, you will know if you have a winner or a bummer. Not really a very big piece of work to try, and if you are not happy with what you see, chop it off and try something else.
Enjoy /s/ Bob
My Eagle is entirely flush riveted, with 3/16" x 120 deg rivets, holding 0.080" thick aluminum 5052-H32 alloy. It is the stuff that 'black boxes' are made of, and can be flanged 90 deg without cracking. The skin is not flanged, but a lot of other stuff that you make is, so it is good for all around use. Costs less than 6061-t6, which must have a x2t to a x4t bend radius. I have had NO trouble with denting, and I put it on 'hot', at about 130f, and there is NO wrinkling in the heat.
Sounds perfect, yes???? ---- Not quite!!!! Go and look at any big airplane which is riveted, (especially if it has had a lot of cat shots) and you WILL see the rivets. Perhaps not immediately, but you will eventually. My Eagle Bus does. I'm not troubled by that, and decided way back that spot blasting and sanding flush rivets was a LOT easier than working around protruding rivets. Yah, I really need to do a corrosion job and re-paint on my Eagle soon, but not today.
On an earlier post, there was mention of using steel for siding. The idea has some real merit. Work it hot, MIG weld the edges -- always locating the edges on the tubing structure. When cool, it will be absolutely drum tight, and won’t loosen and buckle in hot weather. Since it will be tight, it does not have to be very thick -- say if you use ~~0.040” stock would weigh like 1/8” thick aluminum. Metal creep does not occur on the materials we use and at the loads and temperatures that we see.
The edges and seams will fill with bondo quite nicely, and with a continuous – non-moving – weld seam, should hold just great.
Details of the welding -- If I were to try it, I’d not try to use immense sheets. If the scheme works, comfortable sizes will do just as well. Say -- from the baggage bay longeron to the window line, and several feet long, starting and ending on a member. Gap the adjoining pieces ~~ ½” so there is comfortable room for your weld. Try a 1” weld every 3” while you keep the sheet hot and tight with clamps and magnets. Temp of ~~130f is OK, any higher, and you can get burns). Then go back and finish the welds -- still hot. I believe that the process would be a good bit quicker than rivets.
By the time that you have done three adjoining panels, you will know if you have a winner or a bummer. Not really a very big piece of work to try, and if you are not happy with what you see, chop it off and try something else.
Enjoy /s/ Bob