Methods and structural gap filler for one-up assembly

1. A method of assembling a structure, the method comprising:

drilling an injection hole through a first component and a second component;

encapsulating drilling debris generated between the first component and the second component during drilling of the injection hole by injecting a structural gap filler through the injection hole and between the first component and the second component to form encapsulated drilling debris;

drilling a hole through the injection hole and through the first component, the structural gap filler, and the second component; and

maintaining clamp-up of the first component and the second component between drilling the injection hole and drilling the hole.

2. The method of claim 1 , wherein drilling the hole removes at least a portion of the structural gap filler and at least a portion of the encapsulated drilling debris.

3. The method of claim 1 further comprising:

curing the structural gap filler prior to drilling the hole.

4. The method of claim 1 , wherein drilling the hole through the structural gap filler reduces burr production during drilling of the hole.

5. The method of claim 1 , wherein drilling the hole through the structural gap filler propels fragments of the first component away from the structural gap filler.

6. The method of claim 1 further comprising:

positioning the first component relative to the second component; and

clamping up the first component and second component prior to drilling the injection hole.

7. A method of assembling a structure, the method comprising:

drilling an injection hole through a first component and a second component;

encapsulating drilling debris generated between the first component and the second component during drilling of the injection hole by injecting a structural gap filler through the injection hole and between the first component and the second component to form encapsulated drilling debris;

drilling a hole through the first component, the structural gap filler, and the second component, the hole offset from the injection hole; and

maintaining clamp-up of the first component and the second component between drilling the injection hole and drilling the hole.

8. The method of claim 7 further comprising:

curing the structural gap filler prior to drilling the hole.

9. The method of claim 7 , wherein drilling the hole through the structural gap filler reduces burr production during drilling of the hole.

10. The method of claim 7 , wherein drilling the hole through the structural gap filler propels fragments of the first component away from the structural gap filler.

11. The method of claim 7 further comprising:

positioning the first component relative to the second component; and

clamping up the first component and second component prior to drilling the injection hole.

12. A method of assembling a structure, the method comprising: drilling an injection hole through a first component and a second component; injecting a structural gap filler through the injection hole and between the first component and the second component to fill a gap between the first component and the second component; maintaining clamp-up of the first component and the second component between drilling the injection hole and injecting the structural gap filler; and wherein injecting the structural gap filler encapsulates drilling debris generated between the first component and the second component during drilling of the injection hole to form encapsulated drilling debris.

13. The method of claim 12 further comprising:

positioning the first component relative to the second component; and

clamping up the first component and second component prior to drilling the injection hole.

14. The method of claim 12 , wherein injecting the structural gap filler pushes some drilling debris generated between the first component and the second component during drilling of the injection hole away from the injection hole.

15. The method of claim 12 further comprises: drilling a hole through the first component, the structural gap filler, and the second component.

16. The method of claim 15 , wherein drilling the hole removes at least a portion of the structural gap filler and at least a portion of the encapsulated drilling debris.

17. The method of claim 15 further comprising:

curing the structural gap filler prior to drilling the hole.

18. The method of claim 15 , wherein drilling the hole through the structural gap filler reduces burr production during drilling of the hole.

19. The method of claim 15 , wherein drilling the hole through the structural gap filler propels fragments of the first component away from the structural gap filler.

20. A method of assembling a structure, the method comprising:

positioning a first component relative to a second component;

clamping up the first component and the second component to reduce space between the first component and the second component;

drilling an injection hole through the first component and the second component;

encapsulating drilling debris generated between the first component and the second component during drilling of the injection hole by injecting a structural gap filler through the injection hole and between the first component and the second component to form encapsulated drilling debris;

drilling a hole through the injection hole and through the first component, the structural gap filler, and the second component, drilling the hole through the structural gap filler reduces burr production during drilling of the hole; and

maintaining clamp-up of the first component and the second component between drilling the injection hole and drilling the hole.

21. The method of claim 20 , wherein drilling the hole comprises drilling the hole through the injection hole.

22. The method of claim 20 further comprising:

curing the structural gap filler prior to drilling the hole.

23. The method of claim 20 , wherein drilling the hole through the structural gap filler reduces burr production during drilling of the hole.

24. The method of claim 20 , wherein drilling the hole comprises drilling the hole offset from the injection hole.

25. The method of claim 24 , wherein the drilling hole removes at least a portion of the structural gap filler and at least a portion of the encapsulated drilling debris.