Another hiatus...  This time, from this blog.  Still working on the RV-10!!  Tail cone is all riveted.  The oldest mini me helped with the rest of the riveting.  Its starting to look like an airplane now.  This is a big milestone in my book. 

Now it's time for the empennage attach which is in progress.  The elevators have been fitted to the H.S. I'm stuck on actually putting the H.S. on the tail cone though.  I'm missing the raw material to fabricate 2 shims.  Instead of ordering one part, I'm skipping ahead to the elevator trim section mount.

Started the elevator trim mount and stop short again since it's calling out for odd drill bits that did not come with the Cleaveland Tool Kit.  So have a small list of tools I need to order now from Cleaveland including their static port kit.  Although the tried and true rivet head static port Vans recommends, the consensus is it is very flimsy and delicate if messed with after install.   The latest version of the Cleavland Static ports have been accurate as reported by past builders.   Its a much more substantial piece that looks really sturdy AND nice.  The tubing and fittings are superior in quality with quick disconnects. 

Mean while, I have been planning the wing kit order.  So far the plan for the wing build:

Standard build
Gretz Mast
3/4" conduit in each wing
Deluxe Fuel Caps
Duckswoth Leading Edge Light in each wing
OAT Probe
Unsure of wing tip lights at this point.
1 quart of proseal.  (1qt on hand)

For now...  I'm working ALOT to save up for the wing kit.

Stay tuned.

Hiatus...


Its been over two months since my last  update.  Other projects (aquaponics) need my attention.  The RV got ZERO attention during that hiatus.  The break ended 2 days ago...

With the tail cone assembled and clecoed, it was time to start riviting.  The first parts to be rivited are the J stiffners to the skin using 426-3-3.5 rivits.  Boy, I was really nervous riviting for the first time after 2 months on the final assembly of the tail cone.  YIKES!! Well, low and behold, the first 4-5 rivits were bent over.  I didn't fret about it since I expected it.  I also didn't fully rivit to not expand the holes.  After those initial bad rivits, all the others went in smoothly and perfect. 

I recruited the admiral to help buck the center portion of the foward tail cone floor.  I couldn't reach that area at all over the side skins.  We made a good team riviting the floor.  She bent over one rivit close to a bulkhead that she had a hard time squaring off the tungten bucking bar.  I drilled out the 5 or 6 rivets that were bad and reset those with a -4 rivet.  All rivets were check with the gauge and all were good.  Great confidense booster this was. 

Next, I need to rivet the bulkheads to the skins...  No pictures unfortunatley since I didn't want any distractions during the process due to the hiatus.  I'll take some shots next time out though.

Thanks for following...

Till next time...

10 days has gone by since I posted something to the blog.  Thats all that has stopped though.  The build has continued VERY strong.  I'm afraid though that the empennage will be totally complete (including fiberglass) before the wings arrive.  I'll be on the look out for unbuilt wings in the classifieds.  If you know of anyone with RV-10 untouched wing kit, let me know.  I'm looking for a bargain to start wings sooner, otherwise, I'll just continue to save up for the kit from Vans Aircraft. 

Since the last post, The longerons, aft deck, top skins and seat belt brackets were clecod, and match drilled.  With that, came the dissasembly, and deburring of all parts.  The dissasembly is so depressing, lol.  Its exciting to see a huge part being built but then it all comes apart, ugh!  The kids came in one night and asked where the tail cone went.  My daughter thought I stuck it up in the attic.  "No honey, I took it apart."  "Why?"  "The instructions says to take it apart to prepart for final assembly."  "Oh ok."  

Took me 3 days to fully deburr all parts, sand and countersink a few parts.  Those were VERY long days.  A minmum of 10 hours a day, MINIMUM.  Deburring and sanding was extremely tedius.  Only when I got to the last part, a skin, did I need a break.  The though of deburring what seemed like a million holes instantly drained my energy tank.  After a 1hr break doing other things around the house, I was instantly reenergized and finishd the deburring and sanding. 

Next was to dimple and countersink some parts.  I opted to not dimple until after priming.  The dimples make priming (and sanding) a bit more difficult for an even coat.  Ended the night at 2230 after priming all parts.  After bringing all the parts inside at night, I noticed the 8 footish longerons standing up nice and tall by the garage side door, unprimed, ugh!  The next day I was sent home from work early.  I mixed up a small batch of AKZO and sprayed the longerons and touched up a few other parts.  Carmella and Benico wanted to help do some riveting today so after riveting the bellcrank bearing assembly, they helped find rivets, nutplates, and asembly parts by part number.  This is the first time they see parts being riveted together.  They helped place rivtes in holes where needed.  We have another riveting session planned for tonight.  Yesterday we riveted the battery tray.  Tonight we will start with the tiedown bulkhead assembly (had to skip to battery tray since one of the angles were not primed ether, primed it with the longerons). 

Check out the time lapse videos of the last 10 days.  Also don't forget to check out the rest of the videos on my you tube channel and post your questions, suggestions, or comments.  Your input would be greatly appreciated. 

 

 

Tail Cone 3

 

 

Tail Cone 4

 

 

Tail Cone 5



Another day full of match drilling.  Finished match drilling the right side. Flipped the cone right side up.  Clecod the aft bottom skin along with the two rear most bulkheads.   This last two bulkheads were really a tight fit. Next the left stiffners and fling went in. This skin was easier than the right. It might have been easier because I had a game plane after doing the right side. Straight forward, no different than the right side. Baggage stiffner went in too.

A lot of today was wasted on trying to cool the garage.  Todays heat index was at least 100 degrees F. Bought a 14000 btu portable AC a couple nights ago because the central ac took a dump.  After getting the central ac fixed. ( I replaced the capacitor 50 bucks )  I decided to give the portable ac in the garage a try. It dropped the temp in the garage by 2 degrees and 2% humidity after 4 hours!!   Needless to say, it was useless.  I returned it and replace it with a 12000 BTU window unit.   Big difference!! It dropped the humidity from 66% to 49% and temp from 88 to 82 in a couple hours.  A couple more hours and the temp was down to 79.   Temp was set for 79. With the humidity at 49%, this was very comfortable.  This is the biggist unit that would fit the window.  If I find this to still not be sufficient then a split unit will replace the window unit.  Plan on adding attic foil to the attic first though.

It is difficult to work on the build or anything for that matter in the garage when your sweaty and hot as early as 9am.

Any how,  stay tuned for more building!!!!

Today officially starts the start of the tail cone.  Up to this point, I worked on bits and pieces for the tail cone section.  Mainly the fabrication of parts from raw materials.  Because of all those parts had already been fabricated prior today on downtime from the elevators, the tail cone got a big head start.  Started off by pulling out the SUV from the garage (hopefully temporarily until the elevator trailing edges are cured, riveted, off the workbench, and stored).

Vans sent me new 8' J channels a few days ago so today I cut them to the dimensions called out in the plans and deburred.  Next I cut the Cleaveland Tool tie down to size on the band saw and deburred it smooth.  Then I had to come up with a way to lay the bottom skin on to start the assembly process.  Didn't have any saw horses so used a narrow folding table spaced away enough to lay the bottom skin between it and the work bench.   Bulkheads clecoed.  The bottom 3 stiffeners were slid into place, match drilled and clecoed into place.  Next the right side 3 stiffeners were slid into place followed by the right skin.  The right skin was a royal pain in the rear to get the first cleco into each bulkhead.  Really sweated some nuts doing those in the garage.  Glad that was over with.  After the first cleco on each bulk heads were in, then the rest was easy to cleco.  Next was match drilling the right side stiffeners to the skin.  I'm about 95% done with match drilling the stiffeners to the side skin.  My central AC took a dump.  House had not cooled in several hours so I had to stop at about 8pm to investigate.  Turns out the a/c compressor fan capacitor is seems to be toast.  The fan spins only when I kick start the fan.  Back to the RV...I only had maybe 10 more holes to match drill!  errrrr. 

 Here is the time lapse video of today's progress.

Elevator rear spar riveted using RV-10 empennage bucking bar (nice!).  Pop riveted the rib halves. Front spar riveted.  The skins were riveted to the spars.  Trailing edge and foam ribs were bonded and weighted down.  Counter weights attached.  Left trim tab foam ribs were bonded, skin clecoed,  Trim tab placed into the wedge blocks.  Waiting for the bonding to cure before messing with the elevator and trim tab.  Need to order a a new right trim tab skin and spar.  

Here is  a quick time lapse of todays events.

After work today, I finished riveting the the rib halves, and attached the rear spars to the ribs and skins.  Used the RV-10 elevator bucking bar from Cleveland Tools.  When used as instructed in the plans, it works very nicely.  I found clamping the skin to the work bench at the front of the elevator using the wood to protect the skin was even better.  Otherwise, the elevator would move around and rivets weren't as nice.  Here is a quick time lapse of todays work.

It wasn't raining after work today.  After getting home and the sun gone below the horizon, I setup for a quick priming session to touch up spots on some parts needed to assemble the elevators.  Waited about 10 minutes after mixing the 2 part epoxy primer.  PSI set for 20 PSI with HF paint gun trigger pulled, respirator, and eye protection on.  Sprayed the parts, cleaned up the spray gun and took a shower.  Watched a movie (Captain Phillips) with my wife and older son.  After the movie, I brought the parts in and called it a night at midnight.  Tomorrow is another day...  The replacement drill should arrive tomorrow too.

I really need to start taking pictures...

Quick night today.  I promised the wife and kids we would watch Jurassic Park 2 today on Netflix after work today.  So after a quick dinner and a shower I slipped into the garage while the kidos were getting the pop corn and movie ready.  I rechecked the rivets on the rear spar that required bucking with the rivet gauge. A few shop heads were not big enough.  Gave those a few more raps with the 3X rivet gun and bucking bar and all is good now.  Thats it for tonight.

Received an 8 foot PVC pipe today via FedEX from Vans Aircraft.  What a great way to ship the replacement J-channels for the empennage cone.

Also, contacted Cleaveland Tools and they already had a replacement drill in the mail via 2 day priority mail!  Now that is what I call TOP NOTCH service.  They also included a shipping label to return the defective drill!!  Oh yes, I'll be ordering from them again for sure!  Thank you Cleaveland Tools!!  If your on the fence of who to chose for your tools,  go with Cleaveland Tools.  You wont regret it!

I need to post some updated pictures.  I have also been messing around with time lapse videos that will be included in these blogs.

Stay tuned....

Sanded all elevator parts this morning.  Masked off the trailing edge foam rib locations with blue painters tape on the elevators and trim tabs.  Hung the left elevator skins on paracord strung across my side yard just outside of the garage.  Used left over 16 gauge copper wire to thread through the rivet holes to hook onto the paracord.  Perfect for non windy days.  Grabbed two 55 gallon barrels and laid some left over rabbit cage wire with a 1" by 1" mesh on top of them.  This was perfect for the smaller parts.  Used 80cc (combined equal parts) of AKZO to spray the parts.  20 min later, the parts that needed flipping got flipped and sprayed.  20 min later, the parts were bone dry and moved inside for assembly.

Next, I back riveted the rib halves to the skin and noticed a few didn't get a nice coat of prime.  Those remained off to get re primed. Riveted the right rear spar to the rib halves using the squeezer.  I riveted the rib halves to the left top skin backwards.  While drilling out those rivets, the 2 week old Sioux drill took a dump.  Bummer.  That threw me off my game.  I was kind of stuck and couldn't go forward at this point.  I setup for re prime on a few parts and then the sky opened up for the rest of the day.  Went ahead and riveted the right bottom skin to the rear spar.  Some of those rivets required to be drilled out.  Only a few so the Sioux drill worked for those but very very very slowly.   

Can't go further until the last few parts get re primed and get a new drill.  Sent an email to Cleveland Tool to see if they would warranty it and what the process was.  For the most part a productive day that had a few bumps.  The bumps are the learning pains of a newbie builder.  I have to slow down and read the plans multiple time, and double triple check the parts are laid out correctly before doing anything permanent to the airplane.  Sent an email to Vans Aircraft to see if it would be acceptable to up size the drilled out rivets to -4 instead of filling them all up with oops rivets on the rib/skin error.  That is it for today.   Another day of building is in the near future.  Stay tuned...

After work today, I disassembled the elevators to prep for AKZO priming.  Took the skins off followed by the ribs halves, shear clips, gusset and finally the forward spar.  It was a short night since I had already showered.  I didn't want to get covered in aluminum dust.  Tomorrow I'll sand and clean all parts and hopefully AKZO prime all parts.

Still waiting on tools.  Its Sunday and no one is delivering today.  Not UPS, not FedEX, not USPS, NO ONE.  Oh well, I'll skip ahead on the plans and work on something else to make my time productive.  

Picked up 3 hinges and a 2"X8"X 8' that the store cut in half for me.  I could have made the cut at home but didn't wan't to whip out, setup the saw and make a mess for just one cut.  Since I was in the sedan, it was easier to transport too, in the trunk.  

Made a home made break per the plans.  I put in the trim tab and bam, it was bent further.  Not sure why its not bent to it's final angle from factory but oh well, done deal.  I'll set the break aside in case someone wants to borrow it or till the next build....huh???lol.  Oh did I mention I have been loving the build process so far.   Totally up my alley.

Next up was to bend down the trim tab "tabs".  I clamped the skin tight with a c-clamp using wood to protect the skin.  I used a 1/2" scrap piece of plywood about 4" long 2" wide and went at it with a hammer.  I layed the end of the plywood on top of the tab and hit the wood with the hammer firmly. Not blasting away at it but firmly.  As the tab began to bend, the plywood just followed the angle till it was at the desired 90 degree bend.

I used 2 clamps to ensure the skin didn't move.    I did all 8 tabs this way.  Easy peasy.

Next, I cut the elevator counter balance weights.  The band saw made quick work of this task.  Since lead can be nasty, I dawned the safety glasses and respirator.  

Yup, thats me.  Glad I had the safety gear on, The lead was everywhere despite the vacuum connected to the band saw.  

 If you notice I'm jumping all over the place, thats because I'm looking for tasks in the plans that can be done with out the tools in the mail.  Instead of stopping cause I can't get past a step due to missing tool, or what ever the case may be in the future, I skipping along.  When the task is done, I mark the plans the date the step was complete.  Stay tuned....More to come....   Thanks for following!

After spending all morning and most of the afternoon building 2 more tables, I had to put in some time in fabricating airplane parts.  After all, this is about building an airplane right!

Trim Tab Horn

Removed the shaded area using the band saw.  Still need to debur, waiting on scotch bright wheel.  

Skipping ahead: Tail Cone
Still waiting on the bulk of the tools and with nothing to do left on the elevators or elevator trim tabs, started looking over the tail cone section.  Searched for small band saw related work or stuff I could do with the tools already on hand.

Updates on Vertical Stab

The blue stuff I found around some of the rivets was blue tape put on the flat rivet set to prevent marring of the skins.  So that is a non issue now.

Next, this is the email reply from vans regarding the rear spar cap doubler:

This gap looks to me like they missed a step in dimpling/countersinking and you may possibly have a dimple sitting on a flat piece to create this gap. It could also just simply be that when this part was match drilled to the spar it was not clamped tight against the flange. Either way this is not a very desirable situation. I would recommend you dismantle and fix.

Sterling

Van's Aircraft

I'll drill out the left side of the spar cap to make sure there are dimples.  Next I'll put plenty of clamps down to keep the cap flush to the spar then rivet.  I'll put this on hold for now until I have some experience under my belt with drilling out rivets.

Elevator Trim Tabs

After work today, I had my first helpers of the project.  The elevator skins needed more clecos...

Next we photo copied the trim tab rib cutout.  

Carmella cut the rectangles out.  I had some 3m headliner spray glue on hand that we used to glue the templates to the foam.

Next I used the band saw to cut out the 6 trim tab ribs.  This is the first time using the band saw.  Easy peasy. 

My wonderful wife came in and snapped a picture of us pulling the blue plastic off the trip tabs.  She really came out when we were going to bed.  It was 2330.  I smiled and said...."Soon..."

The miter saw in the background is from cutting up 2X4 scrap wood to build more work benches.  Had to use a foldout table for the miter saw which was ok (wobbly) for the quick job.  Ran out of wood so the next morning we picked up more 2X4 and I finished the new work benches.

Elevators

The previous builder started on the elevators and some parts were already riveted.  The tips were riveted, nut plates on one trim doubler were riveted and the control horns were riveted to the front spar.  The plans were marked as to what steps were completed but decided to start from the beginning to double check it all for my peace of mind.  Since today felt like Christmas in May I had to use the clecos to put some parts together.


First was to cut this ribs then celco.  They were already cut, deburred, match drilled, and numbered to include left or right.

Next, The elevator ribs get clecoed to the front and rear spars and bottom skin. All ribs, skins, and spars were previously matched drilled, deburred, and dimpled.

Wow that picture is dark.  The garage is stadium bright which doesn't show in the picture.  Any suggestions anyone?  There a 4 Lithonia LED 4000k 4 ft fixtures in the double car garage.  Each fixture has 2 LED stips in them.  

After this picture, the shear clips when in then I called it a night at 2330.  I was still running on excitement with this first assembly.  I'm sure the tail cone wont go this fast.  The elevators went together quick since most of the work had already been done. Just going through the process of making sure all parts are accounted for and all steps were completed.  Although some parts were already riveted (elevator tip assembly, control horn to forward spar, and right trim nut plates), I plan to prime it as is .  Everything else except elevators was primed by previous builder.

Amazing how strong and stiff these parts get once clecoed together.  Certainly developing the grip of death.

Vertical Stab

After reading the pertinent information in the first 5 sections of the manual, it was time to go through the work of the previous builder.  Although just looking at the rudder as a newbie builder, its a work of art.  Work of art doesn't mean its airworthy though, it is, after all, a critical flight control surface.  Everything in this kit will be scrutinized to the best of my ability using the plans, Vans, and VAF until I deem it airworthy.

Right off the bat (and really hard to see in the picture) seems some rivets were set with the blue plastic on.  On some of the rivets, there are blue specs underneath the rivets. hmmm...  The problem with this is these rivets are not only on the top and bottom ribs,  but also the middle ribs.  So this skin may have to be completely removed or at least ether the top or bottom rib (depending on the which way the middle rib flange faces) in order get to the middle  rivets.

The next area of concern is the left spar cap to rear spar.  The right side does not have a gap but left does as you can see in the picture.  Seems like the previous builder might not have put on sufficient camps on to hold it flush to the rear spar riveting. 

 

 

The gap is small but nonetheless present.  I will shoot off an email to Vans with this post to get their advise.

 

There are 3 holes riveted on the rear spar doubler that were supposed to be left open.  I have added this to the to do list to remember to drill out before empennage assembly. 

 

That's about all the issues I have seen with the vertical stabilizer. 

 

Picking Up the Empennage

After some planning througout the week, the day has come to pick up the FIRST kit of the airplane, the empennage.  The empennage is the "aft" or back part of the airplane that includes the taile cone, horizontal stabilizer, elevators, vertical stabilizer, and rudder.  The rudder, vertical stabilizer and horizontal stabilizers are complete.  The elevators were started but no riviting was done to them yet. 

My son Manny and I woke up bright and early at 0530.  We loaded up the VW Jetta with the horizontal stabilizer cradles built earlier in the week, gobs of tiedown straps, a cordless drill, and patio pillows.  With the fuel gauge needle hovering on the "E" mark, we made a quick stop at the fuel station to top off with diesel.  After the top off, we headed on the Floridas turnpike in search of I-95.  Traffic was nearly nonexistent at this early in the morning at 0600.  Before we knew it, we were in Winter Springs, FL in no time.

We met with Roy at his beautiful property with a separte motor home sized garage/shop.  He took the time to show us his nice work and some mishaps which I gladly appreciated.  We looked over all the asembled parts closely and were happy not to find anything that popped out as unusual (for a newbie builder at least).  The bulk of the parts small to medium parts were in a waist high cardboard box.  The very small parts (rivtis, bolts, nuts, etc.) were in their original Vans packaging or in appropriately sized tupperware type containters.  He offered to do a full parts inventory but with time contraints and parts already assembled, I didn't think that was really feasible. 

With the purchase certain now, we jumped back in the trusty VW and headed up the road some 5 miles to what looked like a an auto wrecker shop.  I was close, it was an auto mechanic shop but WOW, what a dump.  Singed the paperwork for the 15' box rental truck and the fuel gauge didn't match the paperwork.  They gave me the paperwork for a different truck.  Fixed the paperwork and Manny drove the VW and I the box truck back to Roys house.

We loaded the all the parts very carefully over the next 1.5 hours.  The patio pillows came in very handy.  I also rented 24 moving blankets which were essential to protect the all the parts.  Large skins were placed on the floor with 2 blankets in between each blanket.  Rudder and vertical stabilizer were padded with several layers of blankets and secured to the side using the rails.  The horizontal stabilizer was set into the cradle and also secured to the rails with straps.

The ride home with uneventful with a quick pit stop for fuel, food, and empty bladders.  We unloaded the truck into the garage in no time flat.  Returned the truck at a local place and made a stop at the local aircraft hardware shop for supplies.  We built a ceiling hanging shelve out of 2X2 and lamp chain rated for 90 lbs.  The rudder, vertical stabilizer, and horizontal stabilizer with 1/2" foam all went up there easily and out of the way.  All other skins went on to a top shelf also up and out of the way. 

Still need to organize the small parts, and the waist high box full of parts as well. 

Thats it for now.  Took plenty of pictures but cant post them up just yet.  Stay tuned for more....

Killer Deal

I have been working 60-80 hours a week to quickly save up for tools and empennage kits. During downtime, sneak over to VAF.  The classified section received close attention for tools. Well, a partially complete (rudder, vertical stab, horizontal stab complete; elevator started) empennage kit was for sale only 2 hours away in Orlando Florida for $1000!!!  I INSTANTLY replied and got in touch with the seller Roy.  He sent me about 140 pictures that night, and we agreed on the following weekend to meet up.  Thank you Roy!!  This certainly saved money that will not be put toward the wing kit, but also saved a bunch of build time.

Today after work,  built 4 horizontal stabilizer cradles out of some scrap wood.  Remember that fish tank that was scrapped, yup, still reusing the wood.  The H. Stab will be the longest piece to transport at a bit more than 11 feet long.  After some searching online, and texting with Roy, I got the measurements for the H. Stab to build the cradles in advance.

2X4 wood already cut. 

Found the Center and measured 2.5" to each side.  I marked 4.5 but it's actually 5".  The H. Stab is about 4 inches thick.  Added 1" for a bit extra room.

The inside of the vertical 2X4s, are lined up with the above marks then held in place with standard wood screws.  

Meet my little friend hanging out in the cradle hall.

A total of 4 built

Some regular 1" ratchet strap laying around

And here it is. Cradles made with nothing but supplies already on hand.  

Yup, I need better lighting in the garage.  Looks like I'll have to install the lighting sooner than later.  

Stay tuned for more...