You are correct on all counts: this is only for a handful of rivets (32, I think), and they are 3/32", and it's not structural. That would certainly be the simplest, cheapest, and probably quickest.
Lots of great suggestions here! Thanks, everyone!
Ooh! Good idea! It's exactly .032"! Guess I need to get one of those adjustable countersinks. Just watched a video on one the other day (that's how I know of that tool). I borrowed the dimpler from our local EAA chapter. I'll have to see if they have an adjustable countersink.
I've got a 3 1/8" hole. A normal (I think) dimpler is too big to dimple the rivets around the hole, as the "C" part of it bumps into the opposite side of the hole and/or the rivet holes are too close to the hole perimeter (I have one of these, by the way, and it has worked well for some other...
I'm going to patch up some fuselage damage. I'm planning on using a 3 1/8" instrument panel punch to eliminate the damaged area (that's just barely big enough, just about perfect), then using a backer, along with plug to fill that hole for aesthetic reasons. To add a backer to non-structural...
I need to create a patch with a filler piece riveted to a backer with the backer riveted to the fuselage. The material will be .032" 2024. Should I use some kind of sealant between the pieces, or will the (flush) rivets prevent the ingress of rain?
Just to make sure I understand what you're saying, Bill: for a plane like a Luscombe, with a light wing loading, it would be lighter to go with carbon/foam sandwich panels, because I could use thinner layers of carbon fiber, whereas in a fast, highly loaded plane, you'd need enough thickness of...
A couple points.
1) Let's forget the 152.
2) I would probably want to maintain the original VNE of the Luscombe.
3) I don't own a Luscombe yet, but intend on purchasing one. If the one I get comes with a fabric wing, I probably would not follow through with this project, as those wings are...
Is there reason not to? If I made the wings of carbon/foam sandwich panels, then it seems like that would be a nice, simple, light solution.
EDIT: It looks like Bill actually thinks this is a good idea. Will keep reading, watching, and learning.