I am about to start work on a 750 STOL. Do I really need to do primer between the riveted parts, or should I leave it out? I don't see it done in the videos online.

I live in central South Carolina. If I sell it down the line, and the new owner is concerned, he or she could treat it with Corrosion-X or similar, right?

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Me too!

Ditto on Cortec, get one quart from zenith and dilute it w 2 quarts of denatured alcohol,  It goes a long way, that's probably all you'll need.  I apply it with 1" foam brushes from home depot and just discard each brush after use.  It dries quick and it dries clear.  You can also put parts together wet but it should be for the final time because you won't get them apart.

Ken you mentioned your spray can spitting. Did you try pulling the nozzle off and soaking it in lacquer thinner or MEK for a while? Might blow thru it too. That usually clears it out and stops the spitting for me.

I got the mix wrong in my statement above...should be 2 qts Cortec to one qt denatured alcohol. 

I never bothered to pre-mix the entire quart of Cortex - during my build, I just would get a "dollop" of Cortec whenever I needed some and mix it in a plastic medical specimen cup (Ebay).  I diluted mine with distilled water - if the layer is thin enough, it dries pretty quickly. I never actually measured the diluent or the Cortec - I simply thinned it until it flowed smoothly with the disposable foam brush (I believe it was Caleb, the engineer at Zenith, who told me it didn't have to be precisely thinned to a certain ratio - he said just thin it enough to get an even layer of coverage).

Usually, I wound up with 2-3 oz when thinned.  When I was finished with it, I just capped the cup 'til next time.  I only primed contact surfaces, so I still have some of the quart left-over from the build - as pointed out, a little goes a long way!

John

N750A

I went with a can of the Duplo stuff from the local auto parts store. It seems to bond on there really well after scuffing and cleaning the pieces. Nothing to it.

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is primer an insulator? as in prime 2 parts and put them in contact and no current should flow as tested with a volt meter?

Consider electrolysis - it happens even between similar metals.  Add coastal salt air, electricity and you have the perfect trifecta for metal corrosion.  In 30 years the then owner may make it look good, but will it be safe?  Unknown, but would you fly behind it?  Would you expect anyone else too?

Consider Cortec primer - it sprays, it rolls, it brushes. Use it on all surfaces.  It's water borne and relatively safe to apply.  It's also pretty cheap considering the alternatives to not using it.

how would you thin to spray on

I use ZIN/CROM primer from NAPA auto . it is a MARTIN SENOR product in spray cand , self etching on Alum.works very well 

Do you put corrosion protection on every thing or just mating surfaces

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