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Tundra Building Tips

The following procedure will have the outsides of the parts de-burred, leaving only the mating surfaces of the parts to be de-burred. This is particularly useful when doing the wing skins, so they don’t have to be flipped over to de-burr both sides.
1) Cleco parts
2) Drill parts
3) Before moving clecos to finish drilling, de-burr holes just drilled.
4) Move clecoes to holes just drilled
5) Drill parts
6) De-burr remaining holes.
I use a pneumatic drill with a 110 degree countersink (set at the lowest possible pressure)to de-burr holes. The drill should barely be turning and easily stopped using your fingers..

Horizontal Stabilizer
Be sure to use flush rivets on the outer ribs.
Use a flat bar bucking iron when riveting the bottom skin.
Work towards outer aft corners when riveting bottom skin. This way you will only need to use one pulled rivet.

Vertical Stabilizer
Check that leading edge is symmetrical before riveting.

Drill the wing attachment holes in the individual pieces up to just before the final size. Then drill the final size after they are riveted together. If you try and drill up to the final size with all the layers in place, you run the risk of drilling the hole crooked. As me how I know!

Be sure to rivet the intermediate strut attachment points to the front spar. The bend goes forward. This part is not mentioned in the manual.

Installation of turning pulley bracket.
1) DO NOT rivet along the line where the ribs will go!
2) DO NOT install pulleys until installing the cables (immediately before the skin is attached.) Otherwise you will be removing and re-installing the pulleys to install the cables. Nyloc nuts do not like being re-used more than necessary.


Be sure to rivet both the top skin AND the leading edge at he same time. The manual says to rivet the top skin to the front spar and then install the leading edge pieces.

While every builder has their own ideas on just what you need to put together a solid rivet airplane, here is a list of what I felt is needed and what isn't.
Must Have   Don't Need  
Micrometer   Pnumatic Grinder  
Pnumatic Rivet Gun   Cleco jaw clamps  
Pnumatic Drill      
Pnumatic Cleco Tool      

Clecos (at least 500 3/32
250 1/8 and 50 5/32)

Quality drill bits for rivet and bolt sizes 1/16- 1/2 inch      
Long drill bits for rivet sizes      
Drill stops      
Microstop countersinks      
Battery drill      
Custom bucking irons      
Punches slightly smaller then rivet sizes ( for punching out bad rivets)      
Custom bucking tool used when removing bad rivets      
Small 3 inch deep C clamps      
6 inch C clamps      
Files for deburring      
Hand deburring tool      
3M discs      
110 degree countersink (for deburring holes)      
10-100 lb torque wrenches      
Hand squeezer with 1.5 inch jaw      
Tap to clean threads 1/4-20      
Builders bench 4ftx16ft