That is awesome Aircraft1 - thank you so much for the pictures and explanation. I ended up riveting my box back on last weekend. I used Olympic rivets and I will be shaving them down with the shaver tool that I rented from Out of Doors Mart. With that said, if I had to do it over again I think I would use the screw method like you did for a couple of reasons:
1. It is probably easier (at least it would be to me who does not use a rivet gun that often).
2. Being able to take it back off again when needed (I will be polishing mine soon too, but I'll just deal with it not being quite as shiny there as I am not planning on taking mine off again.)
3. Cost - the screw method would be a little less expensive than renting the rivet shaver that I did. This is pretty low priority though, and by itself wouldn't sway me to go with the screws. I would mainly want to go with the screw method because of reasons #1 and #2.
Thanks again for all of your help (and everyone else's too!)
Originally Posted by aircraft1
Just to explain a my madness a little more, I fabricated the interior frames out of .040 2024-T3 alum. these are riveted in place with countersunk # 40 rivets. I was going to use nuts inside with large area washers, I opted for nutplates Then I thought, in the future I would have to access the interior to get to the nuts. No way! you may ask why do you want to remove these exterior frames again? well im focusing on the interior and when I'm ready to detail the frame and polish around this area it will be much easier + if these boxes need to be repaced again then it will be much easier. I'm also changing the cables for the doors, the locks will be replaced and I will fabricate a new bracket to support the box inside to take the weight of off the actual frame (Stress while moving) when the batteries are installed. I included the PN of the screws and you can get these at any aircraft hardware surplus and the nut plates. good luck with your project. share some pics when done. For me I will continue to navigate the forums for knowledge and ideas, and continue my restoration journey. Greetings from southern. HT