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>> The directions call for structural pop rivets to hold the hinge to
the fuselage.  I don't particularly care for pop rivets and I also don't
like to have hinges that I cannot remove (hassle for painting around and
later maintenance). <<

"Structural pop rivets" are not the cheap aluminum or steel rivets you buy
at Home Depot.  They are as strong as standard rivets when used with the
proper spacing a pattern.  Everything has its engineering tradeoffs, and
with blind structural rivets, it is cost.  They are upwards of $1.00 each.
There is no strength penalty.

As for hassle, that is your choice, but these rivets could be drilled
out later for replacement.  Pull the hinge pin for maintenance.  Paint or
mask the hinge, what ever suits you.

As for screws, you could put the nutplates on a backing plate made from
a piece of aluminum, then rivet the aluminum plate to the airplane.  You
still need access to the back side to do this.  You will need to remove the
core material from the back side of this area.


 - Doug Dodson
   Glasair II-S FT
   Flight Test Engineer, CFI-A,G
   Baby Dragon IF1 Race Team
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