Rubber strip replacement

Any DA40 related topics

Moderators: Rick, Lance Murray

User avatar
yl472401
4 Diamonds Member
4 Diamonds Member
Posts: 251
Joined: Sat May 16, 2020 5:02 pm
First Name: Bryan
Aircraft Type: DA40
Aircraft Registration: N890US
Airports: 1C5
Has thanked: 68 times
Been thanked: 24 times

Re: Rubber strip replacement

Post by yl472401 »

Rich wrote: Fri Jun 12, 2020 11:18 pm Bryan, I believe there are through-rivets in the instrument panel but they are covered by some sort of coating or adhesive material. The IPC is dismal in representing any but the oldest instrument panels, but the AMM for the G1000 panel (Pg. 205) seems to show a couple of countersunk holes for rivets right where your bracket came loose:

Screen Shot 2020-06-12 at 16.10.00.jpg
Finally, I took down the panel cover the other day and took some pictures of the Rivets that broke off. Here it is, apparently broke off due to whatever reason. Wonder a regular Rivet gun would get the job done?
Attachments
Rivets back panel.jpg
Diamond DA40, Diamond DA42NG, PPL, IR
User avatar
Rich
5 Diamonds Member
5 Diamonds Member
Posts: 4592
Joined: Mon Aug 30, 2010 12:40 pm
First Name: Rich
Aircraft Type: DA40
Aircraft Registration: N40XE
Airports: S39 Prineville OR
Has thanked: 145 times
Been thanked: 1180 times

Re: Rubber strip replacement

Post by Rich »

yl472401 wrote: Mon Jun 29, 2020 1:42 am
Rich wrote: Fri Jun 12, 2020 11:18 pm Bryan, I believe there are through-rivets in the instrument panel but they are covered by some sort of coating or adhesive material. The IPC is dismal in representing any but the oldest instrument panels, but the AMM for the G1000 panel (Pg. 205) seems to show a couple of countersunk holes for rivets right where your bracket came loose:
Finally, I took down the panel cover the other day and took some pictures of the Rivets that broke off. Here it is, apparently broke off due to whatever reason. Wonder a regular Rivet gun would get the job done?
Those are flush rivets and, I presume, are covered on the panel-viewing side with some sort of film. I don't see pop-rivets working. To do a good job would require some specialized tools/expertise, I would think. Otherwise you'd have this ugly canker-sore looking spot on the panel that would drive you nuts :x Maybe a couple of tiny countersunk screws/nuts could be used? Also look for "hand-rivet squeezers". With the right rivets you could probably pull this off.
2002 DA40-180: MT, PowerFlow, 530W/430W, KAP140, ext. baggage, 1090 ES out, 2646 MTOW, 40gal., Surefly, Flightstream 210, Orion 600 LED, XeVision, Aspen E5
User avatar
Steve
5 Diamonds Member
5 Diamonds Member
Posts: 1953
Joined: Thu Aug 12, 2010 1:23 am
First Name: Steve
Aircraft Type: DA40
Aircraft Registration: N432SC
Airports: 1T7
Has thanked: 81 times
Been thanked: 493 times

Re: Rubber strip replacement

Post by Steve »

If it were my panel, I'd just use the appropriate flat head hex screw, painted to match the panel, and a nyloc nut on the rear. Saves you having to buy/borrow a rivet squeezer. You could also use the appropriate size flush Cherry rivet - you can pull those with a standard rivet tool.
Last edited by Steve on Mon Jun 29, 2020 4:32 pm, edited 1 time in total.
User avatar
yl472401
4 Diamonds Member
4 Diamonds Member
Posts: 251
Joined: Sat May 16, 2020 5:02 pm
First Name: Bryan
Aircraft Type: DA40
Aircraft Registration: N890US
Airports: 1C5
Has thanked: 68 times
Been thanked: 24 times

Rubber strip replacement

Post by yl472401 »

Steve wrote:If it were my panel, I'd just use the appropriate flat head hex screw, painted to match the panel, and a nylon nut on the rear. Saves you having to buy/borrow a rivet squeezer. You could also use the appropriate size flush Cherry rivet - you can pull those with a standard rivet tool.
I’ll consider the option. Thanks fir the advice.Image
Sent from my iPad using Tapatalk
Diamond DA40, Diamond DA42NG, PPL, IR
User avatar
Rich
5 Diamonds Member
5 Diamonds Member
Posts: 4592
Joined: Mon Aug 30, 2010 12:40 pm
First Name: Rich
Aircraft Type: DA40
Aircraft Registration: N40XE
Airports: S39 Prineville OR
Has thanked: 145 times
Been thanked: 1180 times

Re: Rubber strip replacement

Post by Rich »

Steve wrote: Mon Jun 29, 2020 4:24 pm If it were my panel, I'd just use the appropriate flat head hex screw, painted to match the panel, and a nylon nut on the rear. Saves you having to buy/borrow a rivet squeezer. You could also use the appropriate size flush Cherry rivet - you can pull those with a standard rivet tool.
In our "old" panels the heads are exposed and painted over. It appears to me the G1000 panels have some sort of skin on the face that hides the rivets. You need to carefully work around that to avoid ugliness.

Find some guy building a Van's RV and he'll fix you right up. Those guys are rivet-masters by the time they're done :D
2002 DA40-180: MT, PowerFlow, 530W/430W, KAP140, ext. baggage, 1090 ES out, 2646 MTOW, 40gal., Surefly, Flightstream 210, Orion 600 LED, XeVision, Aspen E5
User avatar
yl472401
4 Diamonds Member
4 Diamonds Member
Posts: 251
Joined: Sat May 16, 2020 5:02 pm
First Name: Bryan
Aircraft Type: DA40
Aircraft Registration: N890US
Airports: 1C5
Has thanked: 68 times
Been thanked: 24 times

Re: Rubber strip replacement

Post by yl472401 »

Rich wrote:
yl472401 wrote: Mon Jun 29, 2020 1:42 am
Rich wrote: Fri Jun 12, 2020 11:18 pm Bryan, I believe there are through-rivets in the instrument panel but they are covered by some sort of coating or adhesive material. The IPC is dismal in representing any but the oldest instrument panels, but the AMM for the G1000 panel (Pg. 205) seems to show a couple of countersunk holes for rivets right where your bracket came loose:
Finally, I took down the panel cover the other day and took some pictures of the Rivets that broke off. Here it is, apparently broke off due to whatever reason. Wonder a regular Rivet gun would get the job done?
Those are flush rivets and, I presume, are covered on the panel-viewing side with some sort of film. I don't see pop-rivets working. To do a good job would require some specialized tools/expertise, I would think. Otherwise you'd have this ugly canker-sore looking spot on the panel that would drive you nuts :x Maybe a couple of tiny countersunk screws/nuts could be used? Also look for "hand-rivet squeezers". With the right rivets you could probably pull this off.
Thanks Rich. I’ll try the counter sunk screw first maybe and use Steve's method if it doesn’t worn out.


Sent from my iPad using Tapatalk
Diamond DA40, Diamond DA42NG, PPL, IR
User avatar
Rich
5 Diamonds Member
5 Diamonds Member
Posts: 4592
Joined: Mon Aug 30, 2010 12:40 pm
First Name: Rich
Aircraft Type: DA40
Aircraft Registration: N40XE
Airports: S39 Prineville OR
Has thanked: 145 times
Been thanked: 1180 times

Re: Rubber strip replacement

Post by Rich »

I'm still intrigued by why those rivets sheared off. Or did they pull out? Maybe they weren't properly stressed into place to begin with and vibration took its toll?
2002 DA40-180: MT, PowerFlow, 530W/430W, KAP140, ext. baggage, 1090 ES out, 2646 MTOW, 40gal., Surefly, Flightstream 210, Orion 600 LED, XeVision, Aspen E5
User avatar
yl472401
4 Diamonds Member
4 Diamonds Member
Posts: 251
Joined: Sat May 16, 2020 5:02 pm
First Name: Bryan
Aircraft Type: DA40
Aircraft Registration: N890US
Airports: 1C5
Has thanked: 68 times
Been thanked: 24 times

Rubber strip replacement

Post by yl472401 »

Rich wrote:I'm still intrigued by why those rivets sheared off. Or did they pull out? Maybe they weren't properly stressed into place to begin with and vibration took its toll?
I’d speculate that it wasn’t properly stressed at the beginning and finally gave in after years of pulling from the vibration.


Sent from my iPhone using Tapatalk
Diamond DA40, Diamond DA42NG, PPL, IR
User avatar
yl472401
4 Diamonds Member
4 Diamonds Member
Posts: 251
Joined: Sat May 16, 2020 5:02 pm
First Name: Bryan
Aircraft Type: DA40
Aircraft Registration: N890US
Airports: 1C5
Has thanked: 68 times
Been thanked: 24 times

Re: Rubber strip replacement

Post by yl472401 »

Rich wrote: Mon Jun 29, 2020 4:38 pm I'm still intrigued by why those rivets sheared off. Or did they pull out? Maybe they weren't properly stressed into place to begin with and vibration took its toll?
Here it is. The myth finally got solved. It's a small panel that got bolted onto the metal panel which the small bracket was anchored on with rivets.
Explained by these pictures :D
Attachments
DA40 instrument panel disassembled
DA40 instrument panel disassembled
Diamond DA40, Diamond DA42NG, PPL, IR
User avatar
TomO
3 Diamonds Member
3 Diamonds Member
Posts: 52
Joined: Mon May 09, 2016 2:28 pm
First Name: Tom
Aircraft Type: DA40
Aircraft Registration: N524PS
Airports: KMTH
Has thanked: 3 times
Been thanked: 48 times

Re: Rubber strip replacement

Post by TomO »

What is the wing gap strip adhesive?

May have missed it in reading the posts, but has anyone found out what adhesive Diamond uses to secure the rubber strip to the wing gap or canopy gap.

Tried all types of locally sourced silicon adhesives with good adherence to the paint but poor to no sticking to the rubber strip even after roughing with sandpaper. Contact cement is the same.
I can live with the tape on the wing gap but it will not work with the canopy.

Thanks
Post Reply