|2008-01-25||Sec 8 pg 8-9||Step 4 Final drill all skins, Finished nose ribs.|
|2008-06-16||The kit arrives||Well Fedex ground truck showes up with a very large and heavy box.
The box was almost 12 ft long, 4 ft wide and weighting over 300 lbs.
|2008-06-19||Inventory Begins||Vans aircraft allows 30 days to complete the inventory. After that date, the builder is responsable for anything missing or damaged. They will allow exceptions if you give them a call.
|2008-06-23||Inventory Cont.||Well we are about half way thru the part Inventory all good so far.|
|2008-06-24||Inventory Complete||All the parts are seperated and accounted for. Only 1 small bad is back ordered. Rivits and small parts are seperated and put away.
Glad small food containers work great for rivit storage containers. As well as the freezer bags work well for small parts storage.
|2008-06-26||Page 6-2 Step 1||Step 1 trip vs104 l & r, all went well and Bandsaw on shop smith was a great help.|
|2008-06-27||Page 6-2 Step 2||Fit and trim VS-1014 l & r Match dripp to vs-1003|
|2008-06-28||Page 6-2 Steps 3-6||Fitted and predrilled vs-1017, vs-1008, upper, middle and lower rudder hinge brackets. finsh drilled all parts, sdebured all holes and edges.|
|2008-07-05||Page 6-3 Steps 1-4||Step 1 Debured remaining VS parts, 2 clecoed together remaining VS frame, front spar, ribs and nose ribs. Final drivved all #30 holes in frame.
Steps 3 removed vinal from vs-1001 skin. Clecoed skin to vs frame.
Step 4 Final drilled all skin holes #40.
|2008-07-12||Sec 6 pg 3||Steps 5 Remove VS 1001 VS Skin Debur all holes|
|2008-07-13||Sec 6 pg 5||Step 6 Dimple VS 1001 VS Skin making sure not to dimple holes for fairing panel
Step 7 Disamble VS front spar an ribs, dimple all ribs and front spar. Debur and dimple rear spar
|2008-07-20||Sec 6 pg 5||Step 7 Dimple front spar and nose ribs
Step 8 CS VS 1003 rear spar which are common to VS 1001
Step 9 Disamble rear spar debur all holes
Step 10 Finish dimple VS 1003
Step 11 Final drill rudder attach holes as per plans
|2008-07-21||Primer test||Tested 2 ea primers, 1 Napa 7221 and SEM Self etching primer.
The Napa primrer managed to attach and hold up better then the SEM Primer.
Will go with Napa 7221 primer.
|2008-07-26||Sec 6 pg 4||Step 1 Dimple 4 bottom holes on from spar and CS doubler to match.
Step 2 Debur front Spar
Step 3 Seperate R1007 r1007a rubber stops and striker plates.
Step 4 Debur all r1007 and r1007a
Step 5 Final drill rudder stop hinge holes and debur.
|2008-07-30||Scuff and Prime ALL VS Parts||Scuffed and preped, and primered all VS Parts|
|2008-07-31||Sec 6 Pg 4||Step 6 Rivit rudder stops to bottom rudder hinge bracket.
Step 7 Reassymble VS rear spar Rivit aft spar doubler and lower rudder hinge brackets, and finish all flush rivits on VS Rear spar.
|2008-07-31||Sec 6 pg 5||Step 1 Rivit upper rudder hinge brackets and doubler plate.
Step 2 Rivit VS fwd spar lower doubler to front spar.
Step 3 Assymble VS ribs and spars
|2008-07-31||Pg 6-5 Step 1 2||Step 1 Rivit Upper Rudder hind and doubler
Step 2 Rivit VS Fwd Spar lower doubler to spar.
|2008-07-31||Page 6-5||Step 1 Rivit upper rudder hinge doubler to fwd spar
step 2 rivit lower rudder hinge doubler to fwd spar
|2008-08-02||Sec 6 pg 5||Step 3 Finished install Plastic Smirf tube for wiring to Beacon on top of VS|
|2008-08-03||Sec 6 pg 6||Step 1-4 Install nose ribs and VS Skin to VS Frame, rivit VS skin to Nose ribs.|
|2008-08-03||Pg 6-5 Step 3||Complete steop 3 and install Smirf tube for VS Beacon wiring.|
|2008-08-16||Sec 6 pg 6 Step 5-7||Rivit VS skin to nose ribs, rivit VS Skin to front spar|
|2008-08-17||Sec 6 pg 6 Steps 8 & 9||Complete riviting VS Skin to rear spar and top and bottom ribs and rear spar.
Complete riviting VS 1014 and VS1015 doublers to rear spar.
VS Construction complete
|2008-08-31||Sec 7 pg 2||Setp 1-3
Parts prep Rudder ribs seperate rudder brackes
|2008-08-31||Sec 7 pg 3||Seperate rudder ribs and debur all edges.
|2008-08-31||Sec 7 pg 4 step 1-4||Layout all parts seperated and debured and cleco together r-1002 1003 1010 1015|
|2008-09-10||Page 7-4||Step 5 and 6
Final drill striker plate, machine counter sink as [er plans.
attach bottom rib to spar.
|2008-09-28||Pg 7-5 Steps 1-5||Cleco stiffners 1015 a-f to spar and final drill
Cleco R 607pp 608pp to spar and final drill
|2008-09-28||Pg 7-6 Steps 1-2||Cleco r1012 rib and final drill
cleco r1003 a&b to spar and fuinal drill
|2008-09-28||Pg 7-6 Steps 3||Deburr both rudder skins cleco skins to skelton|
|2008-09-29||Pg 7-6 Steps 4-5||Finish cleco skins to skelton
Cleco trailing edge 1 side
|2008-10-06||Pg 7-6 Steps 6||Work on final drill of skins|
|2008-10-11||Pg 7-6 Steps 6-9||Finish side 1 and final drill side 2
Step 7 Remove Skins and mark
Step 8 Roll slight edge on trailing edge of rubber skins
Step 9 Remove r607pp and R608pp mark spar and side
|2008-10-12||Pg 7-6 Steps 10||Deburr all holes and skins.|
|2008-10-20||Pg 7-6 Steps 11||Dimple all skins and stiffners and ribs|
|2008-10-25||Pg 7-6 Steps 12||Drill countersinks in r1006 trailing edges both sides|
|2008-10-25||Prep and Prime all rubber parts||Scuff and prime rubber parts|
|2008-11-01||Prime Parts||Prime rudder parts|
|2008-11-07||Prime Parts||Finish priming rudder parts|
|2008-11-07||Pg 7-7 Steps 1-4||Step 1 Rivit r1004 together
Step 2 Rivit r608pp and 609pp to spar and nut plates
|2008-11-07||Pg 7-7 Step 5||Rivit r0105 stiffners to rudder skins|
|2008-11-08||Pg 7-8 Steps 1-3||Step 1 rivit top rib half to skins
step 2 rivit bottom rib half to skins
|2008-11-08||Pg 7-8 Steps 1-3||rivit top rib halfs to skins
rivit bottom rib to skins
|2008-11-08||Pg 7-9 Steps 4-8||Rivit lt and rt rudder skins and shear caps.
Seal trailing edge with prc sealent and cleco together
rivit r1004 to left skin.
Sam Beukleman assist
|2008-11-15||Pg 7-10 Step 1||Clean up trailing egde|
|2008-11-15||Pg 7-10 Step 2||Cleco spar to shear caps and rivit into place|
|2008-11-15||Pg 7-10 Step 3-7||Step 3 Rivit r1004 bottom rib
Step 4 Rivit r1003 top ribs together
Step 5 Rivit r1001 skins to fwd spar
Step 6 Rivit counter balance rib to spar
Step 7 rivit counter balance rib to r1001 skins
|2008-11-15||Pg 7-11 Step 1||Back rivit r1001 skins trailing edge|
|2008-11-16||Pg 7-11 Step 2||Curl leading edge and rivit together, a 1 in pipe worked better thin the 1 1/4 pipe as segested|
|2008-11-23||Pg 7-11 Steps 3 thru 6||Step 3 Cleco Skins on tip rib and counter balance rib
Center lead counter balance wright between ribs. Clamp balance weight to rib
Match drill top and bittom holes in balance weight and ribs.
Step 4 temp instal counter balance weight with #8 screws
Step 5 Fold skins just enough to leave a crease then removecounter balance weight.
Step 6 Clam skins between 2 blocks of hard wood, make a radius on the bottom bloce to insure that the bend in the skins will not have a to tight of a radius, thus preventing cracking
|2008-11-23||Pg 7-12 Steps 1-5||Step 1 Cleco Skins to rib and counter balance rib
Drill top and bottom holes with #19 drill. I used a angle drill from the back side worked great.
Dimple ribs and skins as needed,
Install counter balance weight with # 8 screws.
Step 2 deburr all holes put light bend in bothe skin over laps trailing edges. Dimle 2 ea screw holes. Counter skin counter balance weights to accept the skin dimples.
Step 3 Install counter balance weight.
Step 4 IF skin pellows- well they did not so we move on,
Step 5 Rivit remaining 12 match drill holes in skin and top rib and counter balance rib.
|2008-11-23||Sec 8 pg 8-2 Step 1-4||Step 1 Debur Rear spar and HS906 spar doubler
Step 2 Cleco HS906 doubler to rear spar, Drill 4 ea holes from Spar to doubler. Final drill all holes common to HS906
Counter sink 2 ea holes indicated. Final drill 4 ea 3/16 holes
Step 3 Final drill 3/16 center hols on all HS912
Cleco hinge bracktes to rear spar. Final drill #30 holes brackets to spar.
Step 4 remove all parts and mark location. And prep for primer.
|2008-11-24||Step 4||Parts prep for primer|
|2008-11-30||Sec 8 pg 8-3 Step 3-4||Step 3 Make HS108-L From Stock, as per plans
Step 4 Make HS108-R from stock as per plans
|2008-12-07||Pg 8.2 Step 1-4||Step 1 Debur rear spar and hs 906 doubler
Step 2 Cleco HS906 to rear spar and match drill hiles
Step 3 Final Drill HS912 in hs hinges
Cleco HS 912 to rear spar and final drill
Step 4 Disassymble all parts prep and prime
|2008-12-08||Sec 8 pg 8-2 Step 5-6||Step 5 Rivit HS906 to rear spar
Step 6 Rivit Hinge Brackets HS912 to rear Spar
|2008-12-08||Sec 8 pg 8-4 Step 1||Trim material from both ends of HS1013 and HS1014 per plans|
|2008-12-11||Sec 8 pg 8-5 Step 1||Deburr HS102 front spar edges and all holes
|2008-12-14||Sec 8 pg 8-3 Step 1-2||Step 1 Cleco the VA146 between HS911 Final drill 6 holes.
Rivit assembly together
Step 2 Bolt Inboard hinge bracket to rear spar.
|2008-12-14||Sec 8 pg 8-5 Step 2-5||Step 2 HS1013 from end of cap mark 1/4 in from both ends
Nest spar cap and clamp to spar. place mark on the 33rd hole from the end of the front spar.
Match drill 1/8 holes into spar web. Remove spar cap and deburr. Then cleco spar cap to the spar.
Clamp spar cap to flang then match drill 3/32 holes
repeat step on 2nd spar cap.
Step 3 Deburr ans smooth edges on HS1007 front spar doubler.
Step 4 Clamp angle brace to HS1008 and HS1009 to keep square. Match drill 9 ea holes into bracket.
Step 5 Except where called out final drill holes common to the HS1002 front spar and front spar doubler.
|2008-12-20||Sec 8 pg 8-5 Step 6-7||Step 6 Counter sink 8 holes in front spar center top flange.
Match drill 4 3/16 holes common to spar and spar doubler
Step 7 Final drill the middle 9 holes, the counter sink.
|2008-12-20||Sec 8 pg 8-5 Step 8||Step 8 mark parts disassemble, dedur, prep and prime. then reassemble.
|2008-12-20||Sec 8 Pg 8-6||Step 1 Rivit Horv. Stab Fwd spar and spar doubler,
Step 2 Rivit Horv fwd spar attact bracket to fwd spar.
|2008-12-20||Sec 8 Pg 8-6||Step 3 Locate 4 ea hs 1004 remove tabs according to plans
Step 4 Set a side 2 of the ribs from step 3 the remove the small tab as per plans
|2008-12-21||Sec 8 Pg 8-7||Step 1 Debur aall inspar ribs
Step 2 Bend the 2 inboard Inslar ribs 9 degrees for proper aligmnent as per plans
Step 3 Debur the edges of all nose ribs
Radius the ends of each nose rib to prevent smll dents on the leading edge skins.
Step 4 Take 2 ea nose ribs open the end flang by 9 degrees as per plans
Cut a hole in the 2 ea nose ribs as per plans the elv trim cables will pass thru these holes.
Step 5 Fabricate 4 ea craddles Make a template fron a nose rib cleco together with a inspar rin to get th contour.
Off set the trace about a 1/8th of a inch and cover with duct tape.
|2008-12-25||Sec 8 Pg 8-8||Step 1 Cleco the 2 ea nose ribs to the fron spar. Match drill holes not drilled.
Cleco intp position the 2 inboard HS inspar ribs that use the same holes as the 2 center nose ribs.
Step 2 Cleco the remaining nose ribs to the fwd spar Final drill the holes common to the nose rib and the cneter inspar ribs.
Step 3 Cleco thr remaining inspar ribs to the front spar.
Finsl drill all holes common to the inspar ribs and the front spar.
Step 4 Mark nose ribs anf the inspar ribs dso that they go bace to the same position that they were final drilled for.
Step 5 Debur the edges of both the skins. Remove the blue plastic coating on the 2 ea skins
|2008-12-28||Sec 8 Pg 8-8||Step 7 Insert skins into the cradels, angle ends of the skins go into the center,
Step 8 One at a time remove the Nose ribs from the front spar and cleco them to the skins.
Cleco the front spar / inspar rib assyemnby to the nose ribs installed into each skin.
Do not cleco the inspar ribs to the skins yet,
|2008-12-28||Sec 8 Pg 8-9||Step 1 Cleco the hs 1014 and 1015 long and short stringers together, making 2 stringer assemblies. Final drill #30 5 outboard holes on each end of the stinger assemblies. Leave the 8 Inboard holes alone for now.
Insert the 2 stringer assemblies into the stabelizer.
Cleco skins to stringers and ribs.
|2009-01-25||Sec 8 Pg 8-9||Step 2 Cleco Rear spar assembly to the instar ribs tyhen final drill the holes common to the spar and the ribs.
Step 3 Cleco the hs-1016 stringer web to the fwd side of the stringer assemblies. the with a angle drill final drill the holes common to the stringters and stringer web. Match drill the 4 holes in blth flanges of the stringer web into the inspar.
|2009-02-01||Sec 8 pg 8-9||Step 4 Final drill Skins complete
|2009-02-01||Sec 8 pg 8-9||Step 4 Final drill all skins complete
Step 5 Mark holes on inspar ribs and skins for fairing screws.
Step 6 Mark parts during disambley and debur all edges.
Step 7 Dimple 8 ea nose ribs and 2 inspar ribs
|2009-02-04||Sec 8 pg 8-9||Step 7 Dimple Inspar ribs|
|2009-02-07||Sec 8 pg 8-9||Step 7 Dimple Skins Completed
Step 8 Machine counter sink holes in both spar flangesand both stringers
|2009-02-08||Sec 8 pg 8-9||Step 9 Prep and Primer all parts, scuffed and preped stringers, and 9 ea inspar ribs.|
|2009-03-08||Sec 8 pg 8-9||Step 9 HS parts and scuffed ready for cleaning and primer.|
|2009-03-11||Sec 8 pg 8-9||Step 9 Washed and dried all parts prior to priming.
|2009-03-12||Sec 8 pg 8-9||Step 9 Primer HS ribs and stringers.|
|2009-03-14||Sec 8 pg 8-9||Step 9 Primer Forward and aft spars primered all skins.|
|2009-03-14||Sec 8 pg 8-10||Rivit 2 inner ribs to stinger web Rivit 2 sets of HS-1014 and HS1015 together|
|2009-03-15||Sec 8 pg 11||Step 1 Install Snap Bushings in from spar
Step 2 Celco inspar ribs to front spar
Step 3 Rivit Inspar ribs to front spar
|2009-03-16||Sec 8 pg 8-12||Step 1 Put both skins back in the cradels. cleco the HS 905 nose ribs in place, Rivit Nose ribs to both skins with Sam's Help|
|2009-03-18||Sec 8 pg 8-12||Step 2 Insert the front spar/inspar rib assembly into the skins and cleco it to the nose ribs and skins, Rivit the nose ribs to the front spar/inspar rib assembly|
|2009-03-22||Sec 8 pg 8-13||Stepp 1 Install and rivit the last 2 inspar ribs on each side of the HS.
Step 2 Rivit the Skins to the flanges of the front spar, was able to complete rt side tonight.
|2009-03-28||Sec 8 pg 8-13||Step 2 Completed riviting the skins to the front spar flanges
Step 3 Starting from the front spar assembly rivit the skins to the flanges of the inspar ribsup to the Stringer assemblys. 3 of the 4 sides complete.
|2009-03-29||Sec 8 Pg 8-13||Step 3 Rivit skins to the inspar ribs up to the stringer assemblys, completed
Step 4 Rivit the sskins to the Stringer assemblys
Step 5 Rivit the skins to the remainder of the 904 inspar ribs and the remainde3r 1004 ribs.
|2009-03-30||EAA Tech Advisor Inspection||Prior to installing the rear spar. Ed Martinson came to visit and look over all the work so far.
Inspection went great, He looked at:
I was given a excelent work no defects noted.
|2009-04-05||Sec 8 pg 8-13||Step 6 Rivit Rear spar to insspar ribs
install 2 ea snap bushing into the rear spar
|2009-04-15||Sec 8 Pg 8-13||Step 7 Rivit Skins to rear spar
|2009-04-19||Get parts and inventory||gather all needed parts and make sure all is there.|
|2009-04-19||Sec 9 pg 9-2||Step 1 Seperate e1008 and e1022 remove materal as per plans|
|2009-04-25||Sec 9 pg 9-2||Step 2 Debur elevator parts and spars|
|2009-04-26||Sec 9 Pg 9-2||Step 2 Finish deburing parts
Step 3 Cleco e1008 together number and final drill rib halfs
|2009-05-02||PgSec 9 9-2||Step 4 Check flanges on o/b and i/b tip rib flanges are square.
Step 5 Streighten tip rib by fluting between rivit holes.
Step 6 Assemble by cleco together both tip ribs together along with the counter balance skin,
Final drill common holes on ribs and counter balance skin
Final drill 3/16 files to #12
Step 7 Seperate shear clips, deburr and final drill short flange #30
|2009-05-03||Sec 9 Pg 9-3||Step 1 Remove vynal from skins and mark line.
Step 2 Clamp skins between bench surface and a piece of wood with bend line on edge.
Step 3 Form the tab using a small block of wood, finish bend w/hammerfinish 90 dgree with hand seamer.
|2009-05-03||Sec 9 pg 9-4||Step 1 Cleco hinge renforcement plates to front spars then final drill.
Step 2 Final drill trim cable routing hole in both front spars to 5/8
Step 3 Cleco front spar to skins.
|2009-05-03||Sec 9 Pg 9-5||Step 1 Cleco ribs and root rib to the front sparand b ottom skins.
Step 2 Cleco rear spar to ribs and bottom skin.
Step 3 Final drill the 2 end holes at the end of rear spar. Final drill holes common to ribs and spar. Final drill holes common to root rib and spar
Step 4 Cleco e1022 shear clips to the rear spar and the rib.
|2009-05-03||Sec 9 Pg 9-6||Step 1 Cleco trim access renforcement plate to bottom skin.
Step 2 Final drill holes common to renforcement plate and skin and nut plate attachment holes.
Step 3 Cleco elevator gusset to root rib and rear spar.
Step 4 Final drill gussetts
Step 5 Cleco shear clips to reap spar
Step 6 Cleco tip assembly and final drillcommon holes tip to rib and front spar and shear clip.
|2009-05-09||Sec 9 Pg 9-6||Step 8 Insert va140 trailing edge wedge trim to fit. Cleco trailing edge on both elvators.|
|2009-05-09||Sec 9 Pg 9-7||Step 1 Match drill holes in close out tab, tops skins, cleco together then match drill shear clip
Step 2 Remove cleco holding root web cleco elevator horn to fron spar. final drill 6 commaon holes to front spar and root web
Step 3 Final drill top and bottom skins. when drillingfront and rear spar start mid span and work out. Cleco each hole and final drill trailing edge
Left Elevator final drilled.
Step 7 Dissasymble lt elevator mark parts.
|2009-05-09||Sec 9 Pg 9-7||Step 3 Final drill Rt elevator skins.
Step 7 Disassemble Rt elevator and mark parts.
|2009-05-26||Sec 9 Pg 9-7||Step 4 Position elevator trim anchor braqcket on the 2 side cover plates. Final drill holes.
Step 5 Dimple cover plate and re-enforcement plate for #6 screws.
Step 6 Repeat other side.
Step 8 deburr deburr deburr deburr.
|2009-05-31||Sec 9 Pg 9-7||deburr deburr deburr|
|2009-06-06||Sec 9 Pg 9-7||Step 8 Complete deburring,
Step 9 Dimple Skins.
|2009-06-13||Sec 9 Pg 9-7||Step 9 Complete dimple elevator skins.|
|2009-06-13||Sec 9 Pg 9-8||Step 1 Dimple front spar.
Step 2 Dimple rear spar, Machine c/s the i/b 29 holes in the top flange of rear spar.
Step 3 Dimple 3 holes in front spar and rear holes in rear spar.
Step 4 Dimple fwd and aft flanges on e905 root ribs, Dimple top and bottom edges.
|2009-06-14||Sec 9 Pg 9-9||Step 1 Check front and rear spar edge angles
Step 2 Dimple holes in long flange i/b e1022 shear clips.
Step 3 Dimple the flanges of e1008 a&B rib halfs.
Step 4 Dimple 2 holes in the web of e904, dimple the corrisponding holes in the e903 o/b tip ribs.
Step 5 Dimple the top and bottom flanges of e904 and e903 tip ribs
Step 6 Counter sink drill holes in the e1023 trailing edge.
Step 7 Roll slight edge in trailing edge skins.
|2009-06-14||Sec 9 Pg 9-9||Step 1 Check front and rear spar edge angles
Step 2 Dimple holes in long flange i/b e1022 shear clips.
Step 3 Dimple the flanges of e1008 a&B rib halfs.
Step 4 Dimple 2 holes in the web of e904, dimple the corrisponding holes in the e903 o/b tip ribs.
Step 5 Dimple the top and bottom flanges of e904 and e903 tip ribs
Step 6 Counter sink drill holes in the e1023 trailing edge.
Step 7 Roll slight edge in trailing edge skins.
|2009-06-21||Re arange garage||Moved Shop Smith to small garage. Created perment storage for Horz. Stab Bolted to shelf brackets. Rearanged large garage and cleaned up getting ready for empennage assembly.|
|2009-06-21||Sec 9 Pg 9-10||Step 1 Clean and prep and prime parts|
|2009-06-27||Sec 9 Pg 9-10||Step 1 Prep and prime parts|
|2009-06-28||Sec 9 Pg 9-10||Step 1 Prep and Prime parts|
|2009-07-03||Sec 9 Pg 9-10||Step 1 Prep and prime part Finish|
|2009-07-08||Sec 9 Pg 9-10||Step 2 Rivet E903 and 904 tip ribs together
Step 3 Rivet E913 counter balance skin to E903 and 904 Tip ribs, not riveting the last 6 rivets on the skins.
Step 4 Rivet E910 hinge renforcement plates and associated nut plates.
Step 5 Rivit root rib to spar.
Step 6 Install snap bushings
|2009-07-09||Sec 9 Pg 9-10 and 9-11||Step 7 Rivet WD605 LT AND RT to front spar.
Step 1 Rivit nutplates to reinforcement plates.
|2009-07-19||Sec 9 Pg 9-11||Step 2 Rivet reinforcement plates to skins
|2009-07-19||Prep Elevator skins for riviting.||Remove blue protective covering on all rivit lines|
|2009-07-19||Sec 9 Pg 9-11||Step 3 Back rivet rib halfs to back of skins|
|2009-08-02||Sec 9 Pg 9-12||Step 5 Finish riveting aft spar flange on top of rt elevator|
|2009-08-02||Sec 9 Pg 9-11||Step 4 Rivet rear spar to aft ribs only insure to include 2ea shear clips that share rivits to the aft edge.
Step 5 Rivet remaining shear clips to end of rear spar.
Step 6 Rivet gussets to i/b end of spar.
|2009-08-02||Sec 9 Pg 9-12||Step 1 Rivet rear spar to rt bottom skin
Step 2 Rivet rear spar tp lt top skin all rivets except where elevator trimcut out is.
|2009-08-13||Sec 9 pg 9-12||Step 6 Pop rivet rib halfs together with blind rivets on lt elevator|
|2009-08-15||Sec 9 pg 9-12 &13||Step 6 rivet rib halfs with blind rivets on rt elevator
Replace bad rivits on lt elevator that was found where the rivet had split in half.
|2009-08-15||Sec 9 pg 9-13||Step 1 Cleco lt & rt elevatorfront spars to ribs and skins|
|2009-08-17||Sec 9 pg 9-13||Step 2 Rivet front spars to fwd ribs of both elevators|
|2009-08-22||Sec 9 pg 9-13||Step 3 Rivet elevator skins to front spars leaving o/b 6 rivits not set.|
|2009-08-22||Sec 9 pg 9-14||Step 1 Rivet aft flange to root rib
Step 2 Rivet aft i/b corner gusset to root rib
Step 3 Rivet skins to root rib and front spar.
Step 4 Cleco Tip rib to elevator and rivit the assemblt to the shear clip
Step 5 Rivit the tip rib assembly to the front spar.
|2009-08-26||Sec 9 pg 9-14||Step 6 Rivet top and bottom skins to o/b rib and front spar|
|2009-08-27||Sec 9 pg 9-14||Step 7 Cut 4 ea ribs from foam -- Copy templates cut and glue to foam
|2009-08-30||Sec 9 pg 9-14||Step 7 Cut Foam trailing edge blocks|
|2009-08-30||Sec 9 pg 9-14||Step 8 apply feul tank sealent to trailing edge wedge and
insert wedges between slins.
Step 9 Apply fuel tank sealent to trailing edge wedges and cleco the trailing edge together.
Step 10 Place elevators on flat work benches, place 5-6" boards on top and place weight on top of boards holding trailing edges together.
|2009-09-06||Sec 9 pg 9-14 & 15||Step 11 Remove weights and then clecos from trailing edges. Remove any sealent from rivet holes.
Step 12 Rivet trailedges.
Step 1 Finish riveting skins to o/b tip rib
Step 2 Rivit the shear clips to the close out tabs.
Step 3 Make a slight break in leading edge of top skins.
Step 7 Rivit wd415 trim cable attach bracket to cover plate.
|2009-09-07||Sec 9 pg 9-15||Step 8 Remove material as per plans from counter balance lead weights|
|2009-09-12||Sec 9 Pg 9-15||Finish last 4 rivets on o/b rib to Skins|
|2009-09-12||Elevator Review||Ed Martinson EAA 1230 tech advisor review of elevators, no defects noted and was given a excellent job.
|2009-09-12||Sec 9 Pg 9-16||Step 1 Make 6 ea. trim tab Clamp blocks.
Step 2 make foam blocks for the aft edge ofr trim tabs
|2009-09-21||Sec 9 Pg 9-16||Step 3 Layout lines for foam blocks and bend lones
Step 1 Cut wood block wedges.
|2009-09-23||Sec 9 Pg 9-15||Step 4 Roll Leading edge skins
Step 5 Cleco leading edges together with assistance of Tom Mitchel
|2009-09-23||Sec 9 Pg 9-15 and 9-16||Step 4 Roll Leading edge skins
Step 5 Cleco leading edges together with assistance of Tom Mitchel
Step 3 Scuff trim tab skins
Step 4 Finish breaking rear edges
Steo 5 Bent 2 ea tabs on both ends of trim tab
|2009-09-24||Sec 9 Pg 9-15||Step 6 Rivet elevator leading edge skins|
|2009-09-24||Sec 9 Pg 9-17||Step 1 Final drill close out tabs
Step 2 Break leading edges of bottom edge of trim tab skins,
|2009-09-26||Sec 9 Pg 9-17||Step 3 Remove shaded area from trim tab horns
Step 4 Cleco trim tab horns and final drill #40 holes
Step 5 Disassemble and debur all assembly
Step 6 Dimple skins and trim tab horns and close out tabs
Dimple bottom of trim tab spares and counter sinl top of spar.
Step 7 Mask inside skins for the foam ribs and prime all parts.
|2009-09-28||Sec 9 Pg 9-17||Step 8 Rivet front bottom spar to skins and trim tab horns to skins.
Step 9 apply sealent to foam trim tab ribs place inside of trim tabs
Slip clamp blocks on trim tabs over trim tab foam ribs
Cleco top flang to skins and set a side to dry.
Step 10 Rivet close out tabs.
|2009-10-03||Sec 9 Pg 9-17||Remake Rt Elevator Trim Tab due to errors on origional.|
|2009-10-05||Sec 9 Pg 9-17||Work on Rt elevator trim tab, primer parts.|
|2009-10-05||Sec 9 Pg 9-18||Step 1 Cut Trim tab hinge material, @35 inches.
Step 2 Drill #40 hole as per plans.
Step 3 Match drill hinge to elevator.
|2009-10-05||Sec 9 Pg 9-17||Step 8 Replacement Rt trim tab, rivet front spar to bottom of trim tab skin, rivet trim tab actuator horms.|
|2009-10-07||Sec 9 Pg 9-17||Step 9 Seal in foam ribs on right trim tab
Step 10 Rivet bent tabs on trim tabs.
|2009-10-10||Sec 9 Pg 9-16||Step 3 New Lt elevator trim tab skin prep and mask for scuffing
Step 4 Complete trailing edge bends
Step 5 Bend both end close out tabs on lt elevator.
|2009-10-10||Sec 9 Pg 9-16||Step 1 & 2 drill end tabs break bottom edge|
|2009-10-14||Sec 9 Pg 9-16||Step 4 Final Drill skin to spar
Step 5 Disasemble all parts
Step 6 Dimple all holes
Step 7 Mask inside of skin for foam blocks and prime as needed
|2009-10-14||Sec 9 Pg 9-18||Step 2 Drill holes in end of hinge material on rt elevator
Step 3 Drill and cleco trim tab hinge to elevator
Step 4 Drill and cleco rt trim tab to elevator
Step 5 Mark hinge on rt elevator for triming
|2009-10-21||Sec 9 Pg 9-18||Step 5 Mark edge on lt trim tab hinge
Step 6 Remove hinge and prime both hinges in prep for assemble
Step 7 Rivet hinge to lt elevator
|2009-10-22||Sec 9 Pg 9-18||Step 7 Finish riveting trim tab hinge to rt elevator and to both trim tabs.
Step 8 Install hinge pin and trim tabs to both elevators
|2009-10-22||Sec 9 Pg 9-19||Step 1 Drill 1/16 hole for safty wire
Step 2 Bend hinge pin to fit end of elevator and per plans, still needs to be safty wired.
|2009-10-25||Sec 10 Pg 10-2||Step 1 Make F1012E tie down bar, cut to size cut corners, debur
Need to get 3/8 x 16 tap
Step 2 Remove blue vinal from f1012 a & b then debur, cleco together do not use holes associated with f1012e tie down bar
Step 3 Draw line along top and side on aft plate of f1012e tie down bar
|2009-10-28||Sec 10 Pg 10-2||Step 3 Clamp tie down bar to bulkhead and match drill 4 3/32 holes, then cleco in place tne match drill the 3/16 holes.
Step 4 Make the F1011e rudder cable support angle
Step 5 Match drill nutplates on the f1011e and countersink rivet holes
Step 6 Cut the F1011a bulk head stiffner and doubler and debur
|2009-10-28||Sec 10 Pg 10-3||Step 1 Streighten 2 ea F1011c horzontial stab attachment brackets to with in 1/16
Step 2 Finsih the edges of both F1011c then cleco to the F1011d bulkhead Final drill the holes common to attach bar and bulkhead
Step 3 Place F1011a bulkhead on the back of f1011 center stiffner between the sides of the bulkhead and 1/4 of a inch above the holes in the bulkhead
Clamo in place then match drill all the holes in the bottom of the attachment bar and the stiffner and bulkhead with #30 drill
Step 4 Drill holes indicate on plans to 5/8 holes with uni bit
Step 5 Clamp rudder cable angle to F1011 bulkhead and match drill holes
|2009-10-29||Sec 10 Pg 10-4||Step 1 make the horz stab attachment angle per plans
Step 2 match drill 7 holes of the bulkhead into the attachment angle
Step 3 Debur and flute as nessary F1008l and F1008r and F1085 rudder cable bracket and drill common holes
Step 4 Debur and flute F1007 l&r frames and final drill #30 holes
Step 5 Drill 2 ea 5/16 to 5/8 using uno bit
|2009-10-29||Sec 10 Pg 10-5||Step 1 Debur and flute F1006a, b, c, and d bulkheads then cleco together, final drill holes common to f1006a, b, c, d, but not the F1006b bottom
Step 2 Cut 12 F1047 a-g j stingers
Step 3 Cut ends of stringers at 45 degree angles,
Step 4 Remonve vynal from back of stringers
|2009-10-30||Sec 10 Pg 10-5||Step 4 Draw rivet hole center lines along the entire length of j stringers, mark stringers 3/16 from both ends of stringers
|2009-11-01||Sec 10 Pg 10-5||Step 4 Finish drawing rivet lines on the back of the j stringers
and mark both ends of stringer 3/16 from ends
|2009-11-04||Make new saw horses||Needed saw horses tall enought to build tail cone on|
|2009-11-07||Saw horses||Finished making needed saw horses|
|2009-11-07||Sec 10 Pg 10-6||Step 1 Cut 2 ea angles from stock 98 1/8 drill 1/4 in hole at 7 7/16 in from end and cut out shaded areas.
Step 2 Bent Rt longeron at 20 11/16 in 3 degrees
Step 3 repeat step 2 on lt longeron
|2009-11-07||Sec 10 Pg 10-7||Step 1 Place f1078 bottom skin upside down on saw horses and cleco F1007, F1008 and F1011 bulkheads to skin
Step 2 Slide stiffners F1047f thru notches in bulkheads
|2009-11-08||Sec 10 Pg 10-7||Step 2 match drill F1047f l&r
Step 3 Slide F1047g into notches and Center drill and match drill
Step 4 Cleco F1029 l&r bellcrank ribs to fwd bottom F1078 skins final drill 6 ea #30 holes common to ribs and frames
Step 5 Slide assemble to lt side of saw horses then position F1047 c, d, e, stringers into frames
Step 6 Cleco left skin to frames and bulkheads then positin stringers center ends.
Step 7 Center fwd marks on stinger and center rivet line marks on stringers and match drill the skin to the stringers
|2009-11-09||Sec 10 Pg 10-8||Step 1 Flip tailcone over, the cleco bulkhead f1011 and f1079 bottom skin to the f1078 fwd bottom skin and the f1073r side skin
Cleco F1012 a&b bulkheads to aft bottom skin snd both side skins
Step 2 Place remaining F1047c, d, e, stringers into notches of the frames and then cleco F1073 l side slin to the f1079 and f 1078 bottom skins
Step 3 Locate and match drill f1047 c,d,e stringers to f1073l side skin,
|2009-11-18||Sec 10 Pg 10-8||Step 3 completes match drilling stringers to the left side skin,
|2009-11-21||Sec 10 Pg 10-8||Step 4 Splitt F1055 into 2 ea rudder stop stiffners
Step 5 Cleco in place rudder stop stiffners
Step 6 make the f1056 rudder stop brace as per plans
Step 7 Position and clamp in place to the rudder stop stiffiners
Make sure tail cone in not twisted by placing level accross the top of F1073 sides in 2 places
Hold rudder stop brace against the bulkhead and match drill 4ea #40 holes and cleco into place.
remove brace the debur cleco back into place and drill rudder stop stop stiffners to the rudder stop brace with #30 bit
|2009-11-21||Sec 10 Pg 10-9||Step 1 Cleco F1006 bulkhead to the F1073 l&r side skins and the f1029 bellcrank ribs|
|2009-11-22||Sec 10 Pg 10-9||Step 1 Final drill common holes to bell crank ribs and bulkhead
Step 2 Cleco f1028 baggage bilkhead channel to f1028r bellcrank rib and the f1006 bulkhead then final top holes
Step 3 Seperate f1037 bell crank rib adapter into individual parts
Step 4 Final drill 3/32 nutplate holes machine countersink fluse 3/32 holes
Step 5 Final drill for 3/16 holes in both f1037a&b bellcrank angles and 2 identified 3/16 holes in f1037b&c bellcrank rib angles w/#12 drill
|2009-11-22||Sec 10 Pg 10-11||Step 1 Make sure bend in longerons located at the break in the f1073 side skin, then clamp longerons to the f1014 aft deck and side skins. The proper alignment the apex (corners)should be even with the skins over the entire length
Step 2 Match dril the common holes on the f1073 side skins using 3/32 drill
|2009-11-23||Sec 10 Pg 10-10||Step 1 Cleco F1037 b&c bellcrank angles to ribs
Step 2 Final drill #30 holes comman to f1037 b&c angles and f1029 bellcrank ribs and 4 ea holes common to f1028 bulkhead
Step 3 Make f1010b doubler
Step 4 Install f1032 l&r longerons Adjust nothces in f1007 & f1008 frames
final drill and cleco in place service bullitin doubler plates
Step 5 Secure f1010 doubler uin place with double sided tape
Step 6 Cleco f1014 aft deck and the f1011b stop doubler to the f1011 bulkhead then the f1012 a&b bilkheads
|2009-11-25||Sec 10 Pg 10-11||Step 3 Final drill #40 all remaining skin to frame anf skin to bulkhead holes except f1006 bulkhead
Step 4 Final drill all 3/32 which are common to f1012a&b bulkhead websand 3 holes at the top bulkhead webs common to the f1014 aft bulkhead
|2009-12-02||Sec 10 Pg 10-11||Step 5 Final drill skins to frames and bulkheads on the bottom of the tailcone
Finish final drill side skins and sides of bottom skins
|2009-12-02||Sec 10 Pg 10-12||Step 1 Seperate narrow strip from f1074 fwd tailcond skin, set a side to be used later
Step 2 Flip tailcone over then cleco f1009 frame to the front of f1014 aft teck
|2009-12-09||Sec 10 Pg 10-12||Step 2 Final drill common holes to f1014 aft deck #30 drill
Step 3 Heavy flute double tabs on all f1006 f1007 f1008 f1009 bulkheads
Step 4 Insert stiffners
Step 5 Cleco top skins to frame
|2009-12-12||Sec 10 Pg 10-12||Step 6 Final drill f1047 a&b top stringers|
|2009-12-12||Sec 10 Pg 10-12||Step 7 Cleco fwd skins the frame
Step 8 match drill holes in the skins and stiffners
Step 9 Final drill the rest of the holes associated with the top skins
DO NOT DRILL ANYHOLES FOR THE F1006 BULKHEAD
|2009-12-13||Sec 10 Pg 10-13||Step 1 Make f1011d horz stab attachment bar support
Step 2 Make f1012d uo elevator stop
Step 3 Make sure center line drawn on spacer is center of holes then match drill the 4 holes into the f1010 spacer and the f1010a horz stab attachment angle
Step 4 match drill all side holes of the f1014 deck including f1011b stop doubler into the longerons Final drill the 2 holes common to aft deck - longerons and the f1011a horz stab attachment angles using #12 drill
Step 5 Final drill the 1/8 holes of the f1011b stop doubler common to the aft deck and the f1011b bulkhead w/#30 drill and the middle 3/32 holes with a #40 drill
Step 6 Center f1011b atachment support bar angle on the f1011b stop doubler then clamp the f1011c bars
Match drill holes common to the support angle to the f1014 aft deck, the f1011b stop doubler and the f1032 longeron with #30 drill, Final drill the end 2 holes into the longerons using #12 drill.
Step 7 Center the f1012d up elevator stop on the f1014 aft deck, position the horizonital flange of the elevator stop even with the edge of the cut out in the aft deck then clamp in place.
Match drill the holes of the elevator stop into the aft deck and the f1032 longeronwith #30 drill, then final drill with a #12 drill
|2009-12-16||Sec 10 Pg 10-14||Step 1 Remove and store both top skins
Step 2 Position the 3 ea f636 rear seat sholder harnes anchor brackets on the f1032 longeron clamp and final drill 3 holes
Step 3 Final drill hole for static ports
Step 4 Final drill 4 ea holes on the f824 access panel corners w/#28 drill
Step 5 Drill the 8 nutplate attachment holes in both side skins,
|2009-12-27||Sec 10 Pg 10-15||Step 1 Drawline on f1032r skin make sure trim line clears f1006b bulkhead flange
Step 2 Complete disassembly of the tailcone
Step 3 Trim the triangle portion from the f1032r skin
Step 4 Start to debur all holes and edges on all tailcone parts
|2009-12-27||Sec 10 Pg 10-15|
|2009-12-31||Sec 10 Pg 10-15||Step 4 Debur Debir debur|
|2010-01-01||Sec 10 Pg 10-15||Step 4 Continue debor
Down to 2 stringrs and 3 top skins
|2010-01-02||Sec 10 Pg 10-16||Step 1 Machine countersink holes in f1032 longerons
Step 2 Dimple holes in f824 cover plates for #6 screws
Step 3 Dimple all the skins accept holes indicated, bith top skins dimpled and rt side skin dimpled
|2010-01-02||Sec 10 Pg 10-15||Step 4 Finish deburing
Step 5 Dimple 12 holes in small tailcone bottom skin and debur
Step 6 Final drill 11/16 hole in small tailcone bottom skin
Step 7 Dimple #40 holes in F1012b bulkheads, Dimple holes in the f1012a&b bulkheads, dimple the 3 holes in the center flange of f1014 aft deck
Step 8 Machine countersink the f1056 rudderstop brace and the f1012e tiedown brace
|2010-01-03||Sec 10 Pg 10-16||Step 3 finish dimpling sides and bottom skins
Step 4 Dimple all flanges on bulkheads and frames excopt as noted
Step 5 Dimple stringers except center holes on the top center stringer where nutplates attach
|2010-01-09||Sec 10 Pg 10-16||Step 6 Seperate battery channels
Step 7 Final drill f1036b battery channels
Step 8 Final drill F1035 battery and bellcrank mount
Machine countersink #40 holes as indicated and debur edges and holes
|2010-01-09||Sec 10 Pg 10-17||Step 1 F635 b spacer cut fit and debur
Step 2 Cleco together f635 elevator bellcrank assembly
drill #30 files and final drill
Final drill #12 holes at end of bellcrank
|2010-01-13||Scuff and prime parts||Scuff and prime parts|
|2010-02-20||Scuff and prime||Scuff and prime tailcone parts, bulkheads, stringers, and misc parts|
|2010-02-21||Scuff and prime parts||Finish prep bottom skin and 2 side skins, remove blue flim from rivet lines|
|2010-02-24||Sec 10 Pg 10-17||Step 4 Rivet together Elevator bellcrank
Step 5 rivet nutplates
Step 6 Snap tab of f1036b battery channel into the notches and rivet in place.
|2010-02-25||Sec 10 Pg 10-18||Step 1 Rivet f1012 a&b bulkheads together
Rivet f1012a rudder stop, and f1012e tiedown bar
|2010-02-28||Prime bottom and side skins||Finished primering both tailcone side skins and tailcone bottom skin|
|2010-03-03||Sec 10 Pg 10-18||Step 2 Rivet the f1011 bulkhead and the f1011a bulkhead stiffners and f1011c horv stab attachment f1011e rudder cable angle
Step 3 Rivet nutplates to f1011e ruddercable attach angle
|2010-03-06||Sec 10 Pg 10-19||Step 1 Rivet nutplates on f1073 side skins for access panel hardware
|2010-03-06||Install Safe Air Static port system||Install safe air static port fittings on both f1037 side skins
|2010-03-06||Sec 10 Pg 10-19||Step 2 Rivet horz stab mount angle and lt and rt bulkhead doublers to the f bulkhead|
|2010-03-06||Sec 10 Pg 10-19||Step 3 Rivet together f1008 l&r and rudder cable bracket
Step 4 Install 2 ea snap bushings
Step 5 Rivet f1007 frames together
Step 6 install 2 ea snap bushings
Step 7 Rivet F1006d to the f1006 a&c cleco only f1006b bulkheads
|2010-03-06||Sec 10 Pg 10-20||Step 1 Cleco Tailcone together
|2010-03-07||Sec 10 Pg 10-20||Recountersink f1032 for skin dimples finish clecoing tail together|
|2010-03-10||Sec 10 Pg 10-20||Step 2 Rivet stiffners to bottom skin
completed 2 ea fwd o/b stifners and 1 stiffner in 1 section aft o/b
|2010-03-18||Sec 10 Pg 10-20||Step 2 Rivet stiffners to bottom skin and start stringers on right skin|
|2010-03-20||Sec 10 Pg 10-20||Step 2 Rivet stringers on to right skin just about finished stringers in rt skin|
|2010-03-22||Sec 10 Pg 10-20||Step 2 Completed riveting stringers on rt skin, clecoed lt skin in place and completed riveting top row center stringer|
|2010-03-27||Sec 10 Pg 10-20||Step 2 Finish riveting rt side skin to stringers
Step 3 Rivet side skins to bulkheads starting at top and working down
|2010-03-28||Sec 10 Pg 10-20||Step 3 Rivet skins to bulkheads
tried out 1 3/4 round rivet flush set, it works so much better, ordered one from ac spruce.
Waiting for Toms help on several hard to reach rivets
|2010-03-30||Sec 10 Pg 10-20||Step 3 Rivet skins to bulkheads and bottom skins, and lower radisuses of lower side skin bottom edges
Tom Mitchel came to the rescue to help buck rivets that needed 2 people to buck. Tom has over 46 years of aircraft Sheet metal experence and can just about make anything from sheet metal.
|2010-04-03||Sec 10 Pg 10-20||Step 3 Rivet f1012 frames to side skins
Remount rudder stop support bracket the correct way,
Step 4 Rivet Fwd bottom skin to frames and bulkheads
|2010-04-07||Sec 10 Pg 10-20||Step 5 Work on riveting bottom and side skins together
Almost done with fwd bottom skin
|2010-04-08||Sec 10 Pg 10-20||Step 5 Finished riveting fwd bottom skins to side skins
Step 6 Rivet aft bottom skins to bulkheads and side skins
Step 7 Rivet l&r rudder stop skin stiffner to side skins will have to wait for assistance on o/b 2 rivets
|2010-04-10||Sec 10 Pg 10-21||Step 1 Rivet nutplates to bellcrank rib angle
Step 2 Rivet Bellcrank rib angle to bellcrank sibs
|2010-04-14||Sec 10 Pg 10-21||Step 4 Rivet side skins f1073 to longerons f1032|
|2010-04-15||Sec 10 Pg 10-21||Step 3 Rivet bellcrank ribs to fwd bottom skin
Tom Mitchel assist.
|2010-04-24||Sec 10 Pg 10-21||Step 3 Finish riveting bellcrank ribs to f1007 bulkhead
Touch up primer in emp prep for aft dect install
Step 5 Rivet aft deck as per plans
DO NOT RIVET ANY HOLD IN F1014 AFT DECK AREA
Rivet f1009 to aft deck
|2010-04-24||Sec 10 Pg 10-22||Step 1 Rivet f1011b stop doubler to aft deck need to borrow or purchase a 4" #30 rivet set Set all rivets I could|
|2010-04-24||Sec 10 Pg 10-22||Step 2 Temp install bolts from support bar to stop doubler match drill 2 ea holes into attach bar and support angle
Remove support angle debur and prime
Rivet support angle to aft deck unable to rivet 2 ob rivets untill getting new set.
Step 3 Install all 3/16 bolts and final torch
|2010-05-01||Sec 10 Pg 10-22||Step 2 Finished last 6 rivets in aft deck Installed last 2 ea bolts and nuts in aft deck
|2010-05-01||Safe Air Static ports||Installed safe air static air system, ran static lines tube between both side skin fittings
fabracated a bracket to hold t-fitting
Ran tubing to from ot tailcone
|2010-05-01||ELT Mount||Fit final drill, debur, and prime elt mount
Clecoed in place on rt side skin, will perm mount once elt bracket is mounted to plate
|2010-05-19||Wire Runs down tailcone and prep top skins for primer||Drilled 1/2 in holes for wire conduit on let side ot tailcone.
preped both top skins for primer and removed blue plastic on rivet lines
|2010-05-20||AHARS Mount||Fabricated a AHAR mount according to pics from Advanced Flight Systems
Rivet mount to f1007 bulkhead
|2010-05-22||Prime top skins and over laping edge on tailcone||primered both top skins, primered skin overlaping edges on talcone
fabracated 4 each wire tie mounts and riveted to stringers on each side of f1009 bulkhead back by elevator trim motor
|2010-05-23||EAA Tech Advisor Inspection||Ed Martinson EAA chapert 1230 came and inspected the tailcone prior to top skins being put on.
Recieved no defects noted, EXCELENT Work
|2010-05-23||Sec 10 Pg 10-23||Step 3 Attached Elevator bellcrank to bellcrank angles
Step 4 Bolted Elevator bellcrank angles to battery mount
Step 5 Mount battery mount to Bellcrank ribs
|2010-05-23||Reconfig Garage||Reconfig Garage for next chapter and move tailcone to garage floor
Get down Horz stab, make 11/16 spacer block and mount horz stab to work bench top
|2010-05-24||Sec 11 Pg 11-2||Step 1 Install rod ends in elevators
Step 2 Mount work horz stab to work bench
Step 3 Temp install lt elevator
|2010-05-26||Sec 10 Pg 10-23||Step 1 Install stiffners on top of tailcone
Step 2 Cleco top skins in place
Step 3 Rivet aft skin in plane with the help of Rick Summerfelt
|2010-05-27||Sec 10 Pg 10-23||Step 2 finish riveting top skin to tailcone
Thanks so much for your help Rick Summerfelt
|2010-05-27||Sec 11 Pg 11-2||Step 3 continue--
check elevator travel 30 degrees up and 25 degrees down with out obstructions
Step 4 Secure elevator in trail position
|2010-05-27||Sec 11 Pg 11-3||Step 1 Machine E busking to fit into elevator center pivot bushing.
Step 2 Match drill Left elevator to center bushing
Step 3 Remove lt elevator final drill lt elevator horn to 1/4 in
Step 4 Repeat steps for rt elevator
|2010-05-27||Sec 11 Pg 11-3||Step 1 Machine E busking to fit into elevator center pivot bushing.
Step 2 Match drill Left elevator to center bushing
Step 3 Remove lt elevator final drill lt elevator horn to 1/4 in
Step 4 Repeat steps for rt elevator
|2010-05-29||Sec 11 Pg 11-3||Step 5 Install both elevators and secure them in trail position
Step 6 With both elevators in trail position identify which elevator horn is furthest aft = rt elevator
Step 7 Step 7 in the most aft elevator horn locate and drill 3/16 hole 3/8" from the fwd edge and 1/2" the bottom edge
Step 8 measure span between both elevator horns =3/4"
Step 9 Make a drill guide block out of wood ( I used oak) then drill a 3/16 hole 1/2" from bottom of block
Step 10 Insert 3/16 bit into hole and blockto align block then clamp in place
Step 11 Final drill hole with #12 bit using guide block to alogn drill but (should of used a aluminum or steel block)
Step 12 Remove guide block then remove both elevators from horz stab,
|2010-05-29||Sec 11 Pg 11-4||Step 1 Final drill 1/4" hole vertical stab attach hole in the vs1016 vert stab attach bracket
Final drill 4 ea holes common to the vert stab front spar
De-bur and prime
|2010-05-30||misc||Replace 4 ea rivets i did not like in the horz satb
much better now
Ran conduit down lt side of tailcone
|2010-05-31||Sec 11 Pg 11-4||Step 2 make 4 each shims for horz stab fwd mount|
|2010-06-06||Sec 11 Pg 11-4||Step 3 Attach shims to lower sode of horz stab front spar attach brackets w/double sided tape
Step 4 lower horz stab on to the tailcone and cleco in place with center holes on aft spar
match drill 4 #12 holes in the horz stab attach bard using the rear spar web as a guide and insert an3-6a bolts washers and nuts
|2010-06-06||Sec 11 Pg 11-5||Step 1 cut 2x4 6 1/8" long
Step 2 measure aft o/b corners of the horz stab skin to a common rivet on the center line of f1075 tail cone aft skin both measure 94 1/16" exactly
Step 3 match drill f1014 aft deck horz stab attach shims and install 3/16 bolts washers and nuts
|2010-06-09||Sec 11 Pg 11-5||Step 4 Bolt vert stab attach bracket to front spar
Step 5 final drill top 2 3/16 holes in rear spar doubler, bolt vert stab to aft deck aft fuselage bulkhead
|2010-06-10||Sec 11 Pg 11-5||Step 5 final drill remaining holes and install hardware, machine countersink 2 ea bottom holes, match drill #30 then final drill #12 holes on rudder bracket and install hardware|
|2010-06-12||Sec 11 Pg 11-7||Step 1 Step 1 Secure the elevator in trail position
Step 2 Make a template 91.4 degrees, adjust push rod length until angle between the elevator push rid and the bell crank fits template.
Step 3 Tighten jam nuts
Step 4 Double check elevator travel 30 degrees up and 25 degrees down
Step 5 Thread 3/16 jam nuts on rod ends and threaded rod ends into the rudder spar and adj to 3/4" center hole to spar.
Step 6 Bolt rudder to vert stab adjust center and bottom rod ends and tighten jam nuts
Step 7 Check rudder travel and adjust by adjusting lower rod ends
Step 8 measure distance between rudder skin and elevator aft tip 2 and 3/8 both sides
|2010-06-16||Sec 11 Pg 11-8||Step 1 Fabricate 2 ea f1095 trim tab bell cranks brackets
Step 2 Fabricate 2 ea f1095g Trim tab anchor brackets
|2010-06-20||Sec 11 Pg 11-6||Step 1 Bolt Vert Stab to Horz stab front spar attach bracket
Step 2 Bolt elevators to Horz Stab
Step 3 Cut elevator pushrod to 73"
Step 4 Insert threaded inserts into pushrod, measure and mark 6 ea rivet locations, and drill rivet holes with #30 bit, debir and prime pushrod and threaded inserts.
Install threaded inserts and rivet in place.
Step 5 Install elevator push rod into tail cone connecting elevators to bell crank assembly.
Step 6 Check elevator travel is 25 degrees down travel and 30 degrees up travel and adjust stop settings, i had to file the elevator up stop to insure the 30 degrees up travel
|2010-06-20||Sec 11 Pg 11-8||Step 3 Fit trim servo spacer
Step 4 Cleco trim servo spacer and mounting brackets, final drill spacer and mount brackets
Step 5 Cleco trim server spacer to trim mount brackets and trim cable anchors brackets
Final drill 4 corners with #28 bit
Machine countersink the 8 #30 holes
Step 6 Run #40 drill thru the 8 3/32 holes and machine countersink the 8 holes
Run #30 drill thru the 1/8 holes in the close out frame
Step 7 debur all edges and holes
|2010-06-23||Sec 11 Pg 11-8||Primer all trim parts and remove rudder and elevators and Vertical stab|
|2010-06-23||Sec 11 Pg 11-8||Step 8 Rivet trim bell crank brackets and trim cable anchor brackets and nut plates to trim mount bracket|
|2010-06-24||Sec 11 Pg 11-8||Rivet the close out tab flange and 3 ea #8 nut plates|
|2010-06-24||Sec 11 Pg 11-9||Step 1 Final drill trim tab servo link debur and prime and rivet together
Step 2 Install trim bell crank
Step 3 Install trim servo
Step 4 Install trim servo
attach trim servo to bell crank
Step 5 Install trim cables thru trim cable anchors, attach threaded ends to cable and trim bell crank
Test wired trim system and indicators
Tested good and indicators worked as advertised
|2010-06-25||Trim Servo wiring||Worked on trim servo wiring, fabricated trim servo cannon plug mount, wiring and cannon plug wiring
Cannon Plug wired as follows.
Pin 1 White /red
Pin 2 White
Pin 3 White orange
Pin 4 White green
Pin 5 White blue
Pin 7 Ground for shielding
Wire test good thru cannon plug
Ran 5 wire shielded wire down thru conduit
|2010-06-26||Trim servo wiring||Finished cannon plug mount primered and rivet into place,
Mounted servo and connected ground wire.
Fished hangers thru horz stab to assist trim cable installation
|2010-06-26||Sec 11 Pg 11-10||Step 1 Run trim servo full nose up servo retracted adjusted rod ends.
Run servo full directions confirmed no binding
|2010-06-26||Sec 11 Pg 11-10||Step 2 Remove elevator trim cable access panels
Route elevator trim cables through the holes in horz stab
mount elevator trim actuator assembly to the underside of the aft deck
Step 3 Thread elevator trim cable blocks on to both cables
Final drill both elevator trim tab actuator horns #12 bit
Step 4 Adjust trim tab to 35 degrees tab down position attach clevis to trim tabs
Found that when rigged according to the book instructions, the left trim tab does not center up when traveling the other direction
Researched Tim's MYRV10.com site found a better rigging instructions for trim tabs and now tabs move correctly
Lt trim now 34 degrees down tab 0 up flush, RT tab 35 degrees down tab and 24 degrees up. As per specs
|2010-06-27||Sec 12 Pg 12-2||Step 1 Insure mold recesses on elevator tips are square
Step 2 Trim aft edges and trim widths of molded edges
Step 3 Insert elevator tips pushed tightly into the forward edge and drill holes and cleco
Trim elevator tips to fit elevator and contour
Step 6 Trim rudder tip fairing cap flange
Insert into top of rudder and test fit and match drill holes
|2010-06-27||Sec 12 Pg 12-3||Step 1 Trim aft edge on rudder bottom fairing
Step 2 Install rudder bottom fairing and match drill
Step 5 Trim the molded flange on the horz stab front tip
Step 6 Match drill the holes
|2010-06-28||Sec 12 Pg 12-3||Step 7 Make foam pieced as backing for stab tip aft opening and test fit Left side
Found I cut both stab tips wrong will repair in next steps
|2010-06-30||Sec 12 Pg 12-3||worked in rt tip|
|2010-07-01||Worked on repairing booboo||Layed up glass to repair both tips where i cut them to short|
|2010-07-02||Sec 12 Pg 12-3||Step 8 installed foam pieces in horz stab tips and layed up 3 layers of glass over foam|
|2010-07-05||Sec 12 Pg 12-3||Layup repairs as needed to fix booboo
Trimed rt tip repairs looks good will need some filling ready to remove foam
Trimed lt tip needs 2 more layers on bottom edge.
Step 9 Removed foam frm stab tips
|2010-07-08||Sec 12 Pg 12-3||Step 10 lay up 2 layers of glass inside lt tip|
|2010-07-11||Sec 12 Pg 12-3||Step 10 Lay up 2 layers of glass on inside of lt tip
Sand rt tip to contour layed up glass from 7/8/10
|2010-07-11||Sec 12 Pg 12-4||Step 1 Trim width of molded flange on vs109 vert stab tip
Step 2 match drill mounting holes
Step 3 cut foam to glue into place for back edge
|2010-07-12||Sec 12 Pg 12-4||Layup 2 more layers on the lt Horz stab bottom and repair corner on rt tip|
|2010-07-18||Sec 12 Pg 12-3||Sand out layups on both horz stab tips all are good
Layup 3 layers of glass on lt tip in a low spot
|2010-07-19||Sec 12 Pg 12-2||Step 4 Remove Elevator tip debur and dimple elevator tip holes and machine counter sink trip to fit dimples
Step 5 Cleco elevator tips in place and rivet as per plans
|2010-07-19||Sec 12 Pg 12-2||Step 8 Remove rudder tip debur skin holes and dimple
Machine countersink fiberglass tip holes
Step 9 Cleco rudder tip in place and rivet in place as per plns
|2010-07-19||Sec 12 Pg 12-3||Step 11 Debur horz stab tip skin and dimple
machine countersink fiberglass tip holes
Step 12 Cleco tips in place and rivet as per plans
|2010-08-22||Vert Stab beacon mount||Made mold for Vert stab beacon
glassed 3 layors of glass around outside of mold
|2010-08-22||Disasemble Tailcone||disasemble tie rod ends
remove hors stab
store vert stab and rudder
|2010-08-31||Sec 12 Pg 12-3||Step 3 Remove rudder bottom cap tip, debur and dimple skin
Step 4 Install #6 nut plates on to tip countersink tip holes
Step 5 Install tip on to bottom of rudder
|2010-09-01||Beacon mount||Work on beacon mount Fiberglass bottom plate to round tube
|2010-09-02||Beacon mount||Glass beacon mount to vs tip|
|2010-09-06||Beacon mount||Glassed inner side of vs tip to beacon mount|
|2010-09-20||Beacon mount||Glassed outer 2 layers on both sides of vs tip|
|2010-09-20||Tips filling||Sanded filler on horz stab tips, and refilled lt horz stab tip|
|2010-09-21||Beacon mount||Sanded Sert stab tip beacon mount outer glass
Looks great ready for filler
|2010-09-22||Sec 12 Pg 12-4||Step 3 Layup back face of the vert stab tip with 2 layers of glass|
|2010-09-23||Sec 12 Pg 12-4||Layup 2 layers of glass on the back side of vert stab tip aft face|
|2010-09-25||Sec 12 Pg 12-4||Step 4 Debured dimpled for #6 screws installed #6 nutplates on to Vert Stab tip
Step 5 Installed vert stab tip with # 6 screws
Mixed up fiberglass filler and filled glass on Vert stab tip beacon fairing
|2010-09-26||Finish Emp||Sanded filler on vert stab beacon fiberglass fairing
Removed Horz stab completly and stored on garage wall
Mounted Vert stab and rubber to mount on garage wall for storage
Finished running 20 gauge Beaon tip power wire down conduit in tail cone
Touched up primer
|2010-10-02||Make Storage place for Emp in hanger||Made storage shelf in hanger|
|2010-10-03||Parts Invenmtory and Garage Cleaningq||Cleaned and re aranged garage and complete wings inventory, and putaway all hardware in proper places
|2010-10-04||Sec 13||Section 13 main spar was completed by Rob Hickman the person who I purchased the wings kit from
|2010-11-01||Section 14 Page 14-1||Step 1 Flut and check rib flanges, for proper 90 degree angle.|
|2010-11-05||Section 14 Page 14-1||Step 1 Continue fluting and adjusting flang and angles.
Finished fluting and fixing all flanges on all 15 Left wing ribs.
|2010-11-28||Section 14 Page 14-1||Step 1 Fluted Rt wing ribs thru rib 25. Deburred edges and lighting holes on rt wing ribs.|
|2010-12-04||Section 14 Page 14-1||Step 1 Fluted Rt wing ribs 26-30, and deburred all edges and lighting holes.|
|2010-12-04||Section 14 Page 14-2||Step 2 Make 2 ea angles 7 13/16
Step 3 Cut 2 5/8 flat .063 6 15/32
Step 4 Cut 2 ea 5/8 x 1 13.32
Step 5 Clamp torch tube support bracket and spacers with center line shown in holes then match drill.
Step 6 Cleco flange bearing va146 between torch tube support brackets, cleco assembly to the upper and lower flanges of i/b wing ribs. clamp ang;le flush against aft face of torch tube support bracket and i/b face of i/b rib.
Step 7 Match drill i/b rib and angle.
Step 8 Match drill torch tube support bracket face and angle, match drill holes in the VA 146 flang bearing.
|2010-12-11||Section 14 Page 14-2 Rt wing||Step 6 Cleco bracket assembly to rib clamp angle flush to rib and support bracket.
Step 7 Match drill i/b rib and angle
Step 8 Match drill torch tube support bracket face and angle.
Step 9 Cleco flap hinge rib and flap hinge bracket to i/b wing rib and final drill all holes.
Step 10 Cleco flap hinge bracket to o/b wing rib and match drill all holes.
Ream all the flap attach holes in the hinge brackets to 3/8"
|2010-12-11||Section 14 Page 14-3||Step 1 Remove flange top and bottom of a single w1011-r rib
Step 2 Remove the aft flange on o/b wing ribs
Step 3 Cleco ribs to main spar.
|2010-12-15||Section 14 Page 14-3 Rt Wing||Step 3 Match drill #12 upper and lower attach points on all ribs that will be attached with bolts.
Step 4 Final drill all #30 holes in common to ribs and spars.
Final drill all #40 holes common to ribs and wing spar flange.
|2010-12-19||Section 14 Page 14-3 Lt Wing||Step 3 Final Drill all #30 holes common to ribs and spars.
Match drill #12 upper and lower attach points on all ribs that will be attached with bolts.
Step 4 Final drill all #30 holes in common to ribs and spars.
Final drill all #40 holes common to ribs and wing spar flange.
|2010-12-19||Section 14 Page 14-4||Step 4 Disassemble ribs from main spars.
Disassemble flap hinge brackets
Disassemble torch tube supports
And rearrange garage for wing assemblys.
|2010-12-19||Page 14-4 Lt and Rt wing flap hinge brackets||Found all 6 flap hinge brackets had a slight bend to them, due to the punch process- streighten all brackets
Debured Lt and Rt wing alieron torch tube support brackets
These parts are ready for washing and priming.
|2010-12-26||Section 14 Page 14-4 Wing rib deburring spar primed||Debur Lt wing ribs edges, lighting holes, and all final drilled rivet and hardware holes.
These parts are ready to be washed and primed.
Debured Rt wing leading edge, final drilled rivet and hardware holes.
All ribs ready to be washed and primed.
Prep spars for primer on machine edges.
|2011-01-08||Prep ribs for primer||Scuffed aileron support brackets, all flap hinge brackets and rib doublers.
Scuffed Lt wing ribs
|2011-01-09||Wash and prim parts||Washed and primed aileron support brackets, all flap hinge brackets, and left wing ribs.|
|2011-01-13||Prep ribs for primer||Scuffed 6 ea Rt wing ribs in prep for primer with help from the FAT Cat Vaginta|
|2011-01-16||Prep ribs for primer||Scuff 9 Rt Wing ribs in prep for primer|
|2011-01-16||Page 14-3 Lt Wing Flap hinges||Step 5 Cleco w1025 flap hinge ribs and flap hinge brackets to the i/b wing rib and repeat 2 more times to create the assemblies using the lt wing i.b ribs.
Rivet Lt Wing Flap hinges assemblies together
|2011-01-19||Page 14-3 Step 6 Lt wing aileron torch tube support||Step 6 Cleco and rivet the flange bearing and left torch tube support bracket and angle and spacers together.
|2011-01-22||Wash and prime parts||Wash, dry, and prime Rt wing ribs|
|2011-01-22||Page 14-4 Step 1 Drill tooling holes for conduits||Step 1 Drill out fdw tooling holes for 3/8 safe air pitot tube snap bushings. Ribs 6-15
Step 2 Lt and Rt wing enlarge wire run holes to 13/16 for wire conduit
|2011-01-22||Page 14-5 Wing spar protection||Step 1 Apply protective layer of tape near rib attach points to cover the stepper baron the fwd side of the main spar.ew
Step 2 Cleco wing ribs to the main spars
Final drill #40 the fwd most holes in the fwd tabs od the 7 most i/b ribs
Releveled the work benches.
|2011-01-23||Page 14-3 Rt Wing Flap hinges||Step 5 Cleco and rivet rt wing flap hinge brackets to the i/b ribs
|2011-01-23||Page 14-5 lT Wing ribs riveting||Step 3 Lt Wing Rivet all ribs except the most i/b ribs to the spar.|
|2011-01-26||Page 14-5 Step 4 Lt Wing||Step 4 Remove protective tape from spar assembly
Replaced rivets i did not like.
|2011-01-27||Page 14-5 RT Wing spar protection||Step 1 Apply protective tape near rib attach points to cover stepping bars on the fwd spar.
Step 2 cleco ribs to the Rt wing spar and final drill #30 holes except furthest o/b rib
|2011-01-29||Page 14-5 RT Wing Rib riveting||Step 3 Rivet the fwd flanges on all the ribs except the furthest o/b rib
Rivet the fwd most hole on the fwd tabs of the 7 i/b most ribs to the main spar.
Step 4 Remove the protective tape and adhesive residue from the main spar assembly.
|2011-01-29||Page 14-6 Rt wing Spar||Step 1 Install Bolts on upper lower rib attach holes on the i/b ribs and torch nuts to 30" lbs.
Completed Rt wing top row.
|2011-01-30||Page 14-6 Rt wing Spar||Step 1 Install bolts on lower Rt wing spar, and Lt wing upper and lower bolts
Torched all bolts to 30" lbs.
Installed torch seal in all nuts.
|2011-01-31||Page 14-7 Alieron Hinge Brackets||Step 1 Remove 2ea hatched area for the i/b aileron hinge brackets
Step 2 Cleco aileron hinge brackets, spacers and aileron hinge bracket sides together.
Final drill #30 all common attach holes.
Machine countersink the aft holes as indicated on plans.
Step 3 Cleco trimmed aileron hinge brackets, spacers, and aileron hinge sides together.
Match drill #30 all holes common attach holes.
Machine countersink the aft holes as indicated on plans.
|2011-02-02||Pg 15-2 Step 4 Deburr Aileron Hinge Brackets||Debur Aileron Hinge Brackets in prep for Primer|
|2011-02-06||Prime Aileron Hinge Brackets||Scuff clean and prime aileron hinge brackets|
|2011-02-06||Page 15-2 Aileron Hinge Brackets||Step 5 Press 4 ea bearings into W1013A Aileron Hinge bracket
Step 6 Cleco assembles together,
Press the aft ends of the assemblies together to insure that the bearing is seated into the recesses on the aileron Hinge Brackets.
Step 7 Rivet the assemblies together.
|2011-02-09||Pg 15-3 Rear spar doublers||Step 1 On WD 1008d doubler draw a line 5/16 from the rt edge
Step 2 Align the W1007E rear spar doubler nested in the upper flange from underneath the upper flange of the rear spar web and the o/b edge.
Match drill the #30 holes used to attach the doubler plate, using the rear spar as a drill guide.
Match drill the #40 holes common to the rear spar.
|2011-02-10||Pg 15-3 Rear spar doublers||Step 3 Align W1007D sear spar doubler by nesting the upper flange underneath the rear spar upper flange. Center the lines on the spar doubler with most o/b holes in the holes on the rear spar.
Match drill #30 holes used to attach spar doubler, using the rear spar as a template. Match drill #40 holes common to the rear spar and spar doubler.
Step 4 With the W1007D doubler clecoed in place trace the aileron push rod hole in the rear spar on to the doubler plate.
|2011-02-12||Pg 15-3 Rear Spar doublers||Step 4 Remove doubler plates mark and center punch and pilot drill #30 hole in the center of corner radius then drill out holes with a uni bit to the full corner radius.
Cut between the holes, remove remaining material and smooth edges.
|2011-02-12||Pg 15-4 Rear spar Renforcement doubler and spar final drilling||Step 1 Cleco W1007B rear spar reinforcement fork and W1007D center and lt and rt doubler plates aileron hinge i/b bracket assembly the the ribs attached to the main spar
Match drill the common holes between the rear spar and parts and all 3 flap hinge ribs.
Final drill all #30 holes common attach points that has rivets called out on the plans. All holes common to the wing ribs
Final drill the holes common between the lower rear spar web flange and the wing ribs lower aft tab.
Step 2 Machine countersink the bottom row of rivet holes on the W1007C rear spar fork doubler for a #4 flush rivet.
Machine countersink the holes on the upper flange of the rear spar web that correspond with all 3 doubler plates.
Step 3 disassemble all parts and deburr all edges and holes.
|2011-02-13||Pg 15-4 Deburr and dimple rear spar||Step 3 Continue debur all aft spar parts.
Final drill #40 holes and dimple 26 i/b most holes in both rear spars above the rear spar reinforcement fork.
Dimple the holes in the ribs lower aft tabs and holes in both the rear spar bottom flange and rear bottom aft wing rib tabs.
|2011-02-13||Found cracked ribs||Tried to nudge ribs into place with a block of wood, wrong thing to do, ribs cracked. SO ordered 5 ea new ribs and RV-9 Capacitance fuel gauge kit from Vans.|
|2011-02-20||Removed Damaged ribs||Removed damaged ribs
Fluted new ribs
Debured new ribs
Clecoed and final drilled all of the new ribs.
|2011-03-02||Finish repalcement ribs||Finish final drilling and deburing.
Ready to scuff and prime.
|2011-04-09||Prime repalcement ribs, rear spar and doublers||Scuffed, washed and primed all replacement ribs, rear spar and doubler's.
|2011-05-01||Install replacement ribs.||Finished installing replacement ribs|
|2011-05-01||Pg 15-4 LT Wing Assemble and rivet rear spar||Step 4 Re-cleco rear spar. Rivet rear spar and to wing assemble.
Finished Lt wing up to W1007C wing doubler.
|2011-05-15||Pg 15-4 Rivet Lt Wing rear spar||Finished riveting Lt Wing rear spar.|
|2011-05-15||Pg 16-2 Left wing top skins||Step 1 Lay J stringers in cut outs in the top of the wing ribs.
Cleco Top i/b skin. top out board skins, and wing walk doubler, to the main spar, ribs and rear spar.
Cleco j stringers to the wing skins.
|2011-05-31||Pg 15-4 Rt wing rear spar riveting,||Step 4 Rivet rt wing rear spar. Completed all but winf attach fittings and last i/b 5 wing ribs anf center aileron hinge bracket.
|2011-06-02||Pg 15-4 Finish Rt wing rear spar,||Step 4 Finished rt wing rear spar riveting.
|2011-06-02||Pg 16-2 Rt wing Cleco Wing skins to spars and ribs||Step 1 Lay j stringer in cut out in wing ribs
Cleco i/b top skins and o/b top skins, wing walk doublers to wing main and rear spar and all ribs.
Cleco j stringer to wing skins.
Ran short of #40 clecos will go to JC Aero the get a few hundred more.
|2011-06-11||Finish Cleco Rt wing skins||Finished install remaining clecos, marked ribs where j stringer was rubbing on ribs.
Marked skins where skin lap joint starts and ends.
|2011-06-11||Pg 16-2 Rt Wing Skins final drilling||Step 2 Final drill all #40 holes common to top skins, j stringers, wing walk doublers, and ribs.
|2011-06-12||Pg 16-2Rt Wing Final drill nut plate holes||Step 3 Final drill all nut plate holes #19 drill
Dimple the aft most screw hole with #8 screw dimple.
Machine countersink the remaining screw holes for a # 8 screw dimple.
Machine countersink all rivet holes that correspond to the wing walk doublers for a #3 CS rivet.
|2011-06-18||Misc clean up||Removed skins from Rt wing.
Replaced 1 bad rivet in rear spar.
Touched up primer
Drilled front main spar wing skin rivet dimples counter sinks not completed in section 13.
|2011-08-03||Rt wing Stringer Openings||Opened the Rt wing rib openings for the stringers, preventing any rubbing on the stringers and ribs.
|2011-08-04||Pg 16-2 Rt wing top skins lap joint||Step 5 Remove material from rt wing i/b skin to make a very nice skin transition with the o/b skin and i/b skin.
Thinned o/b skin edge down to .020 In. Feathered fwd corner edge.
|2011-08-06||Pg 16-2 Rt wing O/b skin eadge||Step 5 Remove material on Rt wing i/b edge at lap joint.
Step 6 Debur the edges on both i/b and o/b Rt wing skins
Remove blue protective plastic from rivet rows
Debur doubler plates
|2011-08-07||Pg 16-2 Deburing Rt wing to skins||Step 6 Debur Rt wing o/b wing slin|
|2011-08-31||Pg 16-2 Finish Both rt wing skins||Step 6 Finish deburing both Rt wing skins
2 ea inner doubler plates
Both i/b and o/b j stringers
and both wing walk doubler plates
Scuffed inside both top and bottom Rt wing skins and doubler plates
and J stringers
|2011-09-11||Pg 16-2 Dimple Ribs and Rear spar||Finish dimpling Rt wing top skins
Dimple all ribs on Rt wing, except the 4 most i/b ribs
Dimple the top flange of the rt wing rear spar.
Rt wing skins, doublers, and j stringers are ready to be washed and primed.
|2011-10-09||Pg 16-2 Lt Wing Drill and counter sink Lt wing skins||Step 2 Final drill all holes common to the top skins, spars, ribs and stringers.
Final drill the aft most i/b nut plate rivet holes.
Step 3 Final drill all nut plate holes #19 drill bit.
Dimple the aft most screw hole, for #8 screw with flush dimple.
Machine countersink, the rest if the screw holes for a #8 screw dimple
Machine countersink all the rivet holes that correspond to the wing walk doublers and a #3 rivet
|2011-10-16||Pg 16-2 Lt Wing disassebly||Step 4 Disassemble the parts clecoed to the wing assembly,
Open let wing rib j stringer openings to prevent j stringers from rubbing on the ribs.
|2011-10-23||Pg 13-3 Finish Lt Wing countersinking main spar rivet holes||Finished counter sinking Lt Wing rivet holes,
Prep and Primer both top and bottom edges on Lt Wing main spar where wing skins overlaps and rivet for the main spar.
|2011-10-23||Prep Skins for primer||Remove Blue plastic from inside face of both top skins
|2011-10-23||Pg 16-2 Thin down lap joint edges to make a great seam||Step 5 Thin down the lap joint skins o/b skin edge to .020 and ib skin edge to .020 and the ib forward corner to .010
Front Rt wing i/b top skin ob edge not thined enought. removed skin and feathered edge
Looks good now.
|2011-10-24||Pg 16-2 Debur Lt wing skin and doublers, j stringers||Step 6 Deburr Lt wing top ob skins
Remove blue protective plastic
|2011-10-29||Pg 16-2 Lt Wing Debur skins and prep for primer||Step 6 Finish Debur Lt wing top skins, top of ribs and j stringers
Scuffed inside skins prior to dimpling.
|2011-10-29||Pg 16-2 Dimple Lt Wing top skins||Step 6 Dimple both i/b and o/b top skins, j stringers, and all of the top sides of the lt wing ribs, except for the 4 most ib ribs
Everything flits like a glove.
|2011-10-30||Clean and prep and prime all wing skins, j stringers and doublers||Cleaned both wings ib and ob wing skins. J stringers, and wing walk doublers.
Primed all cleaned and prep wing skins, j stringers, and wing walk doublers.
Re positioned work benches to create a level platform for the wings to be riveted together
|2011-10-30||Pg 16-3 Set up Lt on work Benches||Step 1 Place wings on work benches, place blocks as needed, to keep wings level across the tables. Clamp firmly in place.
Step 2 Lay J stringers into slots in ribs,
Cleco top skins to the ribs and spars.
|2011-11-10||Pg 16- Wing top skin riveting||Step 3 Rivet Lt wing top skins on to the ribs, rear spar and J stringers.
Completed 80% of J stringers, Last 2 o.b ribs left,
Completed 80 % of I/b top skin, all but the 4 ea most i.b ribs and nut plates.
Still need to do both main and rear spar.
Assisted by Kerry Roberson,
All rivets look awesome,
|2011-11-17||Pg 16-3 Lt Wing Skin Riveting continue||Step 3 continuing riveting lt wing top skins
With assistance from Kerry Roberson
Man this is looking great,
|2011-12-01||Pg 16-3 Step 3 Finish Lt wing top skins riveting||Step 3 Finished riveting Lt Wing Top skins.
Looks awesome and very clean.
Kerry Roberson assisted with the riveting.
|2011-12-01||Pg 16-3 Rt wing Wing Skin instalation||Rt Wing
Step 1 Palace Rt wing on level tables, clamp wings to tables to secure wings to table. Insure not to twist or distort wings and spars.
Step 2 Lay stingers in rib slots for stingers. Cleco Inboard wing walk doublers, Inboard wing slinks, and outboard wing skins to rt wing ribs, and forward and aft spars.
|2011-12-03||Pg 16-3 Riveting Rt Wing top skins||Step 3 Rt wing top skins riveted as per instructions,
Started in the center of wing skins and worked my way out to the corners. It worked great and skins look awesome
Assisted by Kerry Roberson again, he did a awesome job bucking 863 rivets in each wing.
|2011-12-08||Pg 16-4 Lt and Rt wing Aileron Hinge Brackets||Step 1 Cleco aileron hinge brackets to both wing assemblies
Step 2 Match drill and final drill all homes common to the hinge brackets and the wing assemblies
Step 3 Remove aileron hinge brackets and debur all holes
Step 4 Rivet Aileron hinge brackets to wings with # 4 rivets as called out on the plans
This completes Section 16
|2011-12-11||Sec 17 Pg 17-2 Leading edge Ribs||Step 1 Flute and straighten and adjust flanges on the the left and right leading edge ribs.
|2011-12-11||Sec 17 Leading Edges J Stingers||Step 2 Fabricate 2 ea leading edge j stringers 76 1/8" long
Draw a line down the center 5/16 from edge of the j stringers
Step 3 Modify 2 ea W1009 l&r ribs as per chart. Completed 1 of 3 sets of ribs.
|2011-12-17||Sec 17 Leading Edges Ribs||Step 2 Complete modify 2 ea w1009 l & r ribs, notching ribs as per plans table.|
|2011-12-17||Sec 17 Page 17-2 Leading Edges Building Cradle||Step 4 Create a cradle to hold the leading edge asseblies
Using a rib as a pattern cut out shape in plywood and save for flap cradles.
Cut 2 ea 1x2 rails 57 1/2" long to connect the v blocks just made
|2011-12-18||Sec 17 Page 17-2 Leading Edges Skin Prep||Step 5 Remove the w1019 l&r splice strips from the fuel tank skins
Step 6 De-bur all all edges in the leading edge assembly
Smooth the I/B edges of both fuel tank skins where the w1019 splice strips were removed.
|2011-12-18||Sec 17 Page 17-3 Leading Edges Setup||Step 1 Remove protective plastic from the inside of leading edges skins
Step 2 place leading edge skins into the cradle.
Cleco skins to all the ribs and splice strips.
Then cleco the outboard rib
|2011-12-29||Sec 17 Page 17-3 Leading Edges J stringers||Step 3 Insert j stringer, position j stringer with o/b edge flush with the o/b face of the rib
Align the center line with the holes in the skins then drill and cleco the j stringer to the skins.
Step 4 Final drill all the ribs and splice strips to the skins.
Run a #40 drill thru the nut plate holes in the splice strips.
Final drill the aft row of the main spar attach holes.
Finished the aft holes on the Lt leading edge.
|2012-01-01||Build Wing cradle||Built a wing cradle from plans seen on Vans Air force web site.
Stand made from 2.6 lumber, 3" locking wheels.
It turned out great and extremely strong and ridged.
Still need carpet for the leading edge to sit in.
|2012-01-08||Sec 17 Page 17-3 Leading Edges Lt leading edge||Step 4 Finish final drilling all ribs, splice strips and aft row of main spar attach holes
Final drill splice strip nut plate holes
Step 5 Enlarge screw holes in spar strip to #19 drill bit.
|2012-01-08||Sec 17 Page 17-3 Leading Edges Rt Leading edge||Step 1 Remove blue plastic protective covering.
Step 2 Place leading edge skin in cradle
Cleco splice strip and all ribs into rt leading edge assembly
Step 3 Insert j stringer into leading edge assembly, position stringer flush with o/b rib face and match drill in place, and cleco to skin
Step 4 Final drill all ribs, splice strips and skins
Drill thru aft main spar attach holes on the rt leading edge skin.
Step 5 Enlarge all screw holes in the splice strip to a #19 drill.
|2012-01-08||Sec 17 Page 17-3 Leading Edges RT||Step 6 Disassemble leading edge assemblies
Step 8 de-bur all rt leading edge parts
Prep skins for dimpling, removed protective covering over all rivet lines on both skins
|2012-01-15||Sec 17 Page 17-3 Leading Edges Lt leading edge assemb.||Step 6 Disassemble Lt leading edge assemblies
Step 7 Machine counter sink the nut plate rivet holes in both splice strips
Step 8 Debur all holes and all leading edge parts
Step 9 Dimple screw holes to #8 Screws in both splice strips
|2012-01-15||Sec 19 Pg 19-2 Stall Warning System||Step 1 Remove left wing fuel tank - Not Installed,
Step 2 Cleco access panel hatch doubler to the leading edge skin
Step 3 Drill the 4 corner radius pilot holes
Drill the 16 access hatch access doubler attach holes
Final drill #40 nut plate attach holes
Step 4 Enlarge the 4 corner radius pilot holes to 1/2 inch
cut between the quadrants of the 4 corner
Step 5 Remove the reference tabs from the access hatch doubler
Remove the blue plastic protective cover and debur the parts and skins
|2012-01-16||Sec 19 Pg 19-2 Stall Warning System||Step 6 Dimple the screw holes in the access panel and doubler plate
Dimple all the #40 holes in the doubler plate and leading edge skin
Step 10 Final drill #40 holes the set of nut plates attach holes on the nose of the o/b rib
Final drill #19 the stall warning attach screw holes.
Step 12 Dimple the #40 nut plate holes in o/b rib
Step 14 Final drill both stall warning guide holes in the leading edge skin.
Step 15 Removed the hatch areas between the 2 guide holes and debur in the leading edge skin.
|2012-01-16||Sec 17 Page 17-3 Leading Edges LT &RT Dimple and prep for primer||Step 9 Dimple all ribs, splice strips, stringers,
Step 10 Scuff clean and prime leading edge parts
|2012-01-17||Assemble Dimpler stand||Assemble stand got at Harbor Freight for the DDRT2 Dimpler
|2012-01-17||Sec 17 Page 17-3 Leading Edges Dimple both LE Skins||Step 9 Dimple lt and rt leading edge skins.|
|2012-01-17||Sec 17 Page 17-3 Leading Edges Primer parts||Step 10 Prime all leading edge parts, all but 7 ribs ran out of light
|2012-01-18||Sec 17 Page 17-3 Leading Edges Install nut plates||Step 11 Install 36 nut plates in the splice strips
|2012-01-19||Sec 17 Page 17-3 Leading Edges||Rivet fill the Rt leading edge skin 2 ea stall warning slot guide holes with 3.3 flush rivets.
|2012-01-19||Sec 19 Page 19-2 Stall warning Access plate||Step 7 Rivet nut plates to access panel doubler
Rivet the access panel doubler to the lt leading edge skin
Install access panel
|2012-01-21||Sec 19 Pg 19-2 Stall Warning||Step 13 Rivet nut plate LE rib for attachment screws
|2012-01-21||Sec 19 Pg 19-3 Stall Warning Switch mount brackets||Step 1 Final drill #31 holes in stall warning mount plate and keeper plate
Counter sink #31 holes for #4 Screw
Step 2 Final drill #19 holes in mount plate and keeper plate
Counter sink #19 holes in the mount plate for # 8 screws
Step 3 Debur mount and keeper plates
Primer all parts
Step 4 Assemble stall warning sub assembly insuring vane moves freely
Step 5 Install sub assembly to the splice rib
Adjust the sub assembly until the vane activates and deactivates the micro switch with minimum travel
Step 6 Double check at rest position stall warning vane is perpendicular to the surface of the wing skin
Step 7 Make the that power the stall warning
Step 8 Install wire connectors and tie wiring to the outboard rib
|2012-01-21||Sec 17 Page 17-3 Leading Edges reassemble||Step 13 Cleco Lt and Rt leading edge ribs, stringers, in prep fior riveting|
|2012-01-28||Sec 17 Page 17-3 Leading Edges Riveting Rt||Step 14 Rivet Rt leading assembly together. Ribs, Stringers and all parts
Completed all rivets that i could with out assistance.
|2012-01-29||Sec 17 Page 17-3 Leading Edges Rivet Lt LE||Step 14 Rivet Lt leading edge assembly
Completed as far as i could go with out assistance
|2012-02-02||Sec 17 Page 17-3 Leading Edges Finish Riveting||Step 14 Completed riveting both leading edge assemblies with the assistance of Tom Mitchel
Finished the 6 most forward rivets on the ribs and leading edges
|2012-02-11||Leading Edge Dent removal||Well when one drops a tungsten bucking bar, it is not a good thing. The leading edges take it hard. So Kerry Roberson came out to assist me in getting the dents worked out. They came out great.
|2012-02-11||AOA Sensing ports in the right leading edge||Install AOA kit in the right leading edge.
Mounted 1 sensing port on the top of the right leading edge and one on the bottom of the right leading edge. Ran the tubing thru the leading edge, thru the hole in the wing spar down thru the pitot tube hole in each rib.
|2012-02-11||Pg 17-4 Attach leading edges to the front wing spar||Step 1 Enlarge wing tie down holes to 3/8", so that the eye bolts used for tie downs can fit thru the skins.
Step 2 Remove any clecos holding the outboard rib to the main spar and the aft flange of the rib.
Check the rt leading edge to insure the tie down rig fits in to the tie down fitting.
|2012-02-18||Made 4 ea Capacitance Plates for the fuel tanks||Made 4 ea plates to fit the RV-10 ribs and mounting hardware|
|2012-02-19||Capactenance plates||Worked on the fuel tank Cap plates drilled ribs for mounting of nut plates.
Drilled ribs for mounting of plates
|2012-02-19||Pg 17-4 Leading edge attachment||Step 2 removed Cleco from the outboard rib.
Cleco leading edge assembly to the wing. Found wing skins to ne 1/32 to long. Removed leading edge and files down the leading edge skins on the long points. re clecoed leading edges back on to the wings.
Step 3 Rivet o/b leading edge rib and o/b rib on both leading edges.
Step 4 Rivet the remaining leading ribs to thw wing spar on both wings
Step 5 Rivet leading edge skins to the main spar. Rt wing top leading edge skins riveted.
|2012-02-23||Pg 17-4 Leading edge attachment||Step 5 Finished riveting the rt leading edge skins to the wing spar.
Rivet the Lt leading edge skins to the wing spar
Both leading edge top skins to be finished with the assistance of a friend.
|2012-03-03||Fuel Tank Capactance Plates||Dimple nut plate attach holes.
Drilled ribs to 1/4" for plastic tubing (anti grounding)
Riveted nut plates to sensing plates
|2012-03-03||Pg 18-2 Fuel Tank Rib||Step 1 Flute all fuel tank ribs as needed.
Finished Fluting Tank Ribs
|2012-03-04||Pg 17-4 Finish Last top flange in left leading edge||Step 5 Finishing riveting lt leading edge top row on skin to spar rivets.
With the assistance of Kerry Roberson
|2012-03-04||Pg 18-2 Fuel tank stiffners||Step 2 Layout as per plans and trimmed to length.|
|2012-03-07||Debur Parts||De-bur Fuel tank stiffeners and Vent Line tabs
|2012-03-08||Pg 18-2 Fuel Tanks||Step 3 Trim tank attach Z brackets and de-bur
I/B Z bracket nut plates
Step 4 Fabricate 2 J stringers 64 1/4 long
Draw line down center of j stringer on each one
|2012-03-11||Pg 18-2 Fuel Tank Skins||Step 5 Remove the blue protective plastic on the inner side of both
fuel tank skins
Debur both tank skins
Cleco the Fwd lt tank stiffeners and fuel drain flange to lt tank
|2012-03-18||Pg 18-2 Fuel Stiffners and ribs||Step 5 Final drill stiffeners and fuel drain.
Match drill the most i/b stiffeners to the skins, then remove and trim leaving 1/4" on the bottom and most aft stiffeners from newly drilled holes.
Step 6 Cleco ribs into the tank skins
Man it was a bear and a fight to get then ribs to fit nice, but i won the battle. And now all ribs fit nicely and are clecoed in place.
|2012-03-31||Pg 18-2 Final Drill Fuel tank ribs to tank skins||Step 6 Final drill all rt tank ribs to skin
|2012-03-31||Pg 18-3 Rt tank J stringer||Step 1 Position J Stringer so that there is 1/4" from the end of the j stringer to the first hole.
Then match drill J stringer to the fuel tank skin. And Cleco in place.
Step 2 Cleco tank attach bracket to the fuel tank skin and the inner nose rib.
Final drill attach bracket to the tank skins and inner nose rib.
Step 3 N/A I am using the Deluxe fuel cap and flanges.
Step 4 Fit and drill fuel cap flange and vent tube clip.
Use the fuel cap opening to center the flange to the tank skin opening.
|2012-04-01||Pg 18-2 Step 6 Lt tank ribs and skins||Step 6 Cleco ribs to lt fuel tank skin.
4 ribs really fought me will finish the step in a few days
|2012-04-12||Pg 18-2 Lt fuel tank rinb and skins||Step 6 Finish cleco ribs to skins
Figured out a much better way to get ribs to fit the ribs to skins.
Final drilled skins to ribs.
|2012-04-18||Pg 18-3 Lt tank J stringer||Step 1 position j stringer in skins and ribs. with a 1/4" from the end of stringer and on center line.
Drill #40 holes align center line on j stringer with holes in skin then match drill.
Step 2 Cleco lt tank attach bracket to the let tank ski and inner nose rib.
Final drill all holes in thank attach bracket
Step 3 N/A I used the Deluxe fuel cap kits
Step 4 Fit and drilled fuel cap flange and vent clip
|2012-04-26||Pg 18-4 Lt tanl Z brackets||Step 1&2 are complete on both tanks except for drilling holes for the nut plates
Step 3 Cleco the aft tank baffles and z brackets to the tank ribs aft flanges
Note the orientation of the Z brackets and the most i/b Z bracket has no nut plates on it.
Step 4 Cleco the the fuel tank baffles to the fuel tank skins
|2012-04-30||Pg 18-4 Rt Tank Z brackets||Step 1&2 are complete on both tanks except for drilling holes for the nut plates
Final drill all rivet holes
Step 3 final drill all z brackets to the rt tank aft baffles to the ribs
Step 4 Cleco the tank skins to the upper and lower flanges of the tank baffles.
|2012-05-12||Pg 18-4 Rt fuel tank baffle||Step 4 Complete the final drilling of rt skins to the upper and lower tank baffles
Step 5 Final all screw holes with # 19 drill in both tanks.
Prep skins rt skins for machine counter sinking of the aft baffles #3 rivets
|2012-05-14||Pg 18-4 Rt Fuel tank Skins||Step 6 Machine counter sink the row of holes that attach the fuel tank skin to the aft baffle
To insure proper alignment on the reassembly leave every 10th hole not counter sank
|2012-05-19||pg 18-4 Lt fuel tank baffle||Step 3 Final drill all Z brackets to the fuel tank rib aft flanges
Step 4 Final drill tank skins to the upper and lower flange f the tank baffle
Step 5 Final drill all screw holes # 19 bit
Step 6 Machine counter sink all skin aft row of rivet holes that attach the aft baffle and the skins, leaving every 10th hole not counter sank.
Step 7 Permanently label all Z brackets for there position in the assembly
|2012-06-04||De-burr Tank attach brackets||Complete de-burr of parts|
|2012-06-04||Rt & Lt Tank Z brackets||Counter sink all rivet holes for nut plates on fuel tank attach brackets|
|2012-06-14||Prep and primer Z brackets||Prep and primer all z brackes|
|2012-06-16||Pg 18-4 Step 1 Install nut plates on z brackets||Rivet nut plates to Z brackets
Step 8 Mark tank skins for rib, stringers, and fuel cap locations\
Counter sink rivet holes in fuel cap flange to accept #3 rivet dimples for .032 skins
|2012-06-17||Pg 18-4 Lt Tank Dissamble||Step 8 Disassemble Lt tank parts, and start deburring
Made cover plate for Old style fuel qty indicator access hole.
|2012-07-12||Pg 18-4 Deburr all tank parts||Finished deburring all tank ribs, stringers and misc small parts for both tanks.
Fabricated tab for fuel vent lines that rivet to the fuel cap flange
Deburred tanks lower and upper tank stiffeners
|2012-07-16||PG 18-4 lt tank skins prep||Deburr Lt tank skins|
|2012-07-19||Pg 18-4 Lt Tank Debirring||Finished deburring Lt tank skin
Removed blue protective plastic from rivet rows
Started to scuff inner skin rib areas on skins
|2012-07-26||Lt Fuel tank||Prepped Lt tanks inside skins for scuffing.
Tapped off stringer and rib lines for proseal
|2012-07-29||Lt Fuel tank prep for sealing||Finished scuffing inner part of skin all rib and stringer areas, for fuel tank sealant bonding.'
|2012-07-29||Pg 18-5 Fuel Tank attach bracket||Step 1 Separate top and bottom shims from each other and deburr edges
Step 2 Final drill holes in top and bottom shims and deburr
Step 3 Study plans until there is no questions on how the fuel tank attach bracket is installed
Step 4 Dimple #19 holes in outer holes where nut plate attaches
Dimple the #40 holes in the k1100-8 nut plates
Rivet the nut plates to the shims
Step 5 Attach VA146 bearing and MS21051 nut plates and top and bottom shims to the lt tank attach bracket
Counter sink let fuel tank attach bracket #40 rivet holes for dimpled fuel tank skins.
|2012-08-01||Pg 18-4 Fuel Tank Skins dimling||Step 8 Dimple lt fuel tank skin, with #3 Fuel tank dimple dies
Dimple #8 screw holes along aft and o/b tank skins.
|2012-08-02||Pg 18 -4 Dimple Ribs and stringers||Step 8 Finished dimpling ribs, stringers
Scuffed parts as needed.
|2012-08-16||Pg 18-5 I/b Aft rib Lt wing||Step 6 Fabricate Filler plate and seal into fuel tank access hole for fuel sending unit.
Step 7 Attach and seal anti rotation plate to lt I/B rib and fuel tank flange
Set #6 Rivets in all tooling holes in both i/b and o/b ribs and seal over
|2012-08-18||Pg 18-5 Sealing fuel tank stiffeners||Step 8 Seal and cleco in place stiffeners to lt fuel tank skin
Seal Lt fuel tank drain fitting to bottom on skin
Seal the rivet heads on the i/b aft rib filler plates and set rivets
Step 9 Seal and cleco in place the lt fuel cap flange to let tank skin
|2012-08-20||Pg 18-5 Lt tank stiffeners||Step 8 Finish Wet riveting all the lt tank stiffeners|
|2012-08-23||Pg 18- Lt Fuel tank wet riveting||Step 8 Wet rivet fuel drain fitting
Step 9 Wet rive fuel cap flange and vent attach tab
Sealed all stringer fillets
Sealed Fuel cap flange fillet
|2012-08-25||Pg 18-5 Sealing rivet buck heads||Step 8 sealed all lt tank stringer buck heads
|2012-08-26||Pg 18-5 Lt Fuel Tank Rib sealing||Step 8 seal all Lt tank ribs in place and cleco
Will let sit for 24 hours or so then wet rivet
Step 10 Wet rivet #7 I/B nose rib into place and seal inside fillet
|2012-08-27||Pg 18-5 Lt tank wet riveting ribs to skins||Step 10 continue riveting Tank ribs to skins
Completed as far as I can go with out assistance on the each nose part of each rib.
|2012-08-29||Pg 18-5 Fuel Tank Rib riveting||Step 10 continue Riveted ribs 5 and 4 on the lt tank with Dan Moors help
|2012-09-02||Pg Lt Tank wet riveting of main ribs||Step 10 Starting I/b and working out board and finish riveting all ribs to the tank skins.|
|2012-09-05||Pg 18-5 Lt Fuel Tank Stringer||Step 11 Rivet Lt tank J stringer to tank skins. Was a real pain and I learned what not to do.
Figured out to make sure to clean the sealant off the shop head of the rivet before setting. Makes setting wet rivets 100 percent easier.
|2012-09-30||Prosealed fillets||Prosealed all fillets on all ribs, stringers, and stiffners as needed.
|2012-10-27||Pg 18-5 Lt Tank Attach Bracket||Step 12 sealed and clecoed fuel tank attach bracket on lt fuel tank.
Sealed J stringer rivet buck tails and top o/b rib rivet buck tails with sealeant
|2012-10-28||Pg 18-5 Lt Tank Attach Bracket||Step 12 Wet rivet fuel tank attach bracket|
|2012-11-03||Lt Tank Fuel Capacitance Plates||Test fit and trim Cap plates on both I/b rib and O/B rib.
All plates fit great
Drilled snap bushing to allow #18 wire to pass threw with vent line
|2012-11-04||Lt Tank Rivet head sealing||Finished dealing the shop head of all the rivets in the ribs, stringers and fuel tank attach bracket.
Fillet sealed tank attach bracket to skins
Sealed rivet heads on I/B tank rib
|2012-11-10||Pg 18-6 lt Tank Vent line||Step 1 Install snap bushings in tank ribs
Step 2 fabricate vent line out of 5052 aluminum 63" long and flare I/B end of the line for a #4 an fitting
Step 3 Seal and Cleco 7 I/B aft Rib in place
Step 4 Install wiring for fuel tank Capacitance sender plates
Solder wire to BNC connector center pin
|2012-11-11||Pg 18-6 lt Tank I/B rib install||Step 5 Wet rivet the I/B aft rib in place and to the Tank Attach Bracket
Step 6 Connect fuel vent line to bulkhead fitting on I/B rib
Seal I/B rib fillet seal
Sealed bulkhead fitting and fuel vent line.
Sealed wire on the BNC Connector for Capacitance wiring.
|2012-11-18||Left Tank Fuel quantity indication plates||Installed Lt tank Capacitance Plates OHMS tested wiring test good and no shorts
Fillet sealed the outer edges of the most I/B aft rib
|2013-01-20||Pg 18-8 Lt Tank Baffle||Prep tank for aft baffle install.
Cleaned all ribs, skins, removed loose sealant
Wiped down all ribs and skins with MEK
Step 1 Applied sealant to the fuel tank skin forward of the rivet line. Using a max 3/16 bead of sealant.
Put a bead of sealant along the inside edge of the flanges on each end rib
Put a heady bead of sealant where each corner of the baffle meets the end ribs.
Put a thin layer ion the ribs back flanges of the tank ribs
Installed and clecoed the baffle in place, in every rivet hole of the tank skin to baffle joint.
Rear baffle sealant looks great inside the tank from what i can see.
|2013-01-23||Pg 18-8 Lt Tank Baffle||Step 2 Install tank baffle rivets to the tank rear rib baffle rivet
twirl the rivets in proseal before installation
Step 3 Apply sealant to the bottom of each Z bracket dipped rivets in sealant before installing.
|2013-01-26||Pg 18-8 Lt Tank Baffle||Step 4 Rivet baffle to tank skins
Step 5 Install fuel cap
Sealed up tank for testing. Let tank sit for 2 weeks before testing for leaks
NO leaks found
|2013-01-27||Pg 18-4 Rt Fuel Tank||Step 8 Disassemble clecoed together rt fuel tank
Worked on deburring all parts, skins, ribs, stringers and stiffeners
|2013-01-30||Rt Tank Deburr Deburr Deburr||Step 8 Continue deburring parts|
|2013-02-02||Pg 18-4 Prep and deburr Rt tank skin||Remove blue protective plastic on in side of tank skin
Remove blue plastic from rivet rows
Dimple all stringers and 3 ribs
|2013-02-03||Pg 18-4 Finish dimpling and Start Pg 18-5||Finish dimpling ribs, and tank skins
Dimpled all #8 screw holes on trailing edges and o/b edges.
Pg 18-5 Fuel tank attach bracket
Step 1 Separate 5 b and c shims
file tabs and deburr
Step 2 Final drill both top and bottom shims and deburr
Step 3 Confirm position of shims
Step 4 Dimple #19 holes in 1005b shims
dimple 2 ea K1100 nut plates and rivet shims and nut plates
Step 5 Attach va146 bearing and rivet in place
|2013-02-05||Pg 18-5 Rt Tank ribs||Step 6 Riveted #6 rivets in all machine holes in O/B #14 rib and I/B #8 nose rib, Will proseal over both sides of these rivets
Step 7 Proseal fuel tank flange and anti rotation plate on the most I/B aft rib. Sealed cover plate over fuel sender access hols
Step 8 Proseal in place all skin stringers, and fuel drain fitting
|2013-02-11||Pg 18-5 Rivet Fuel tank stiffners||Step 8 Rivet skin stiffeners to skins|
|2013-02-17||Pg 18-5 Fuel drain and doubler fillets||Step 7 Rivet fuel tank anti rotation plate to I/B aft rib
Rivet fuel sump drain fitting on rt tank skin
Fillet seal all tank skin stiffeners top and bottom of skin
Seal fuel cap flange in place
|2013-02-23||Pg 18-5 fuel tank skins||Step 9 Rivet fuel cap flange and vent tube clip to tank skin
Proseal all buck tails on rt tank stingers
Rivet the panel cover plate on the I/B aft rib
Sealed buck tails and rivet heads
|2013-02-24||Pg 18-5 Rt tank ribs and pressure test Lt tank||Step 10 Sealed and clecoed all ribs in place except the I/B aft rib
Setup Lt tank up for leak pressure test.
Aired tank up until balloon was almost full
Will check in the morning to see if balloon is still full
|2013-02-25||Lt Fuel tank leak test||Well the balloon was empty the next morning. I will have to soak tank down with soapy water, and determine were the leak is.
Man this is stressful byt I will figure out where the leak is.
|2013-03-02||Lt Fuel Tanl leak test||Filled lt tank with air. Soaked down tank with soapy water, found the balloon it self leaking. MAN WHAT A RE-LEAF No other leaks noted.
Re taped fitting where balloon attached to. Reinstalled balloon and filled tank with air again. Next day balloon was still inflated. No leak noted.
|2013-03-03||Pg 18-5 Rivet Rt tank Skins||Step 10 Rivet Ribs to tank skins
Started with i/b fwd rib moving o/b
Started to rivet the next o/b rib but sealant past 2 hours work time will continue the next day
|2013-03-06||Pg 18-5 Contiune Rivettin Rt tank ribs||Step 10 Continue riveting rt tank ribs to skin with wet rivets (Proseal)|
|2013-03-31||Pg 18-5 Continue Riveting Rt tank Ribs||Step 10 Continue riveting rt tank ribs to skin with wet rivets
Things are going very slow due to family needs.
Family always comes first!!!!
|2013-04-03||Pg 18-5 Rt fuel tank ribs riveting||Step 10 Continue riveting rt tank bottom ribs to tank skin. Completed all Ribs on the bottom except the most o/b rib
Finished the 2nd most i/b top rib to skin rivets except the last 5 I will need assistance with.
|2013-04-06||Pg 18-5 Rt fuel tank finish riveting ribs to feul tank skin||Step 10 Completed Riveting all ribs except i/b top aft rib to the fuel tank skins
|2013-04-07||Pg 18-5 Rt tank Stringer||Step 11 Proseal the top stringer in place. Fillet seal the fwd edge
Fillet sealed the i/b nose rib and the next o/b rib on the i/b side
Fillet sealed the fuel cap flange
|2013-04-10||Pg 18-5 Finish riveting the Ribs forward nose rivets||Step 10 With the assistance of Dan Moore help, we finished the last of the nose rivets on all the ribs, that i could not do by my self.
|2013-04-21||Pg 18-5 Rt fuel tank Rivet J stringer||Step 11 Rivet J stringer with wet sealant rivets to tank kin|
|2013-04-27||Rt Tank Fillet sealing||Tape off all ribs and J stinger fir pro seal fillet sealing of all seams.
A very slow and process but very important
|2013-04-28||Rt tank fillet sealing||Pro sealed all ribs to skin seams, all j stringer to skin seams.
Turned out very nice.
|2013-05-12||Pg 18-5 Rt tank Fwd attach brackt||Step 12 Pro sealed rt tank attach bracket in place
Clecoed attach racket to the fwd nose rib
Sealed all fuel tank skin rivet buck tail rivet heads
|2013-05-13||Pg 18-5 Rivet Rt tank fwd attach bracket in place||Step 12 Rivet Rt tank fwd attach brackt in place with wet rivets to tank skins|
|2013-05-25||Pg 18-6 Rt Tank vent line||Step 1 modify snap bushing to allow wire to pass thru along witht he vent tube.
Step 2 Cut 1/4" tubing to 63" long
Place sleeve and nut on tubing and flare the i/b end of tube.
Step 3 Install vent line into tank and hand bend line to fit vent line clip and bushing on the o/b part of the tank, and hand bend the i/b end to fit the i/b most rib bulkhead fitting.
Step 4 Install bulkhead fitting into the i/b aft rib
Remove 6 each rivets on the fuel tank flange
The rivet heads were standing proud and not flush, needed to be replaced
|2013-05-27||Pg 18-6 Rt Fuel tank i/b aft rib||Step 5 apply pro seal to the flanges of the i/b aft rib and Cleo in place, will let dit a day before riveting in place
Set the 6 ea removed rivets in the fuel tank flange with wet rivets. Looks much better now.
|2013-05-30||Pg 18-5 Riveting the Rt tank i/b Aft rib||Step 5Wet rivet the i/f aft rib to skin.
Rivet the fwd flange to the Tank attach bracket with the assistance of Kerry Roberson,
|2013-06-08||Rt ful tank indication system||Wired up and soldered the bnc connector and installed into the i/b rib
Ran wires to both capacitance plates in series with each other.
Need to get 4 ea longer mount screws fro JC Aero Supply
Sealed the edges of all wire connectors and the back of the bnc connector inside the tank.
|2013-06-16||Rt fuel tank fuel quanity indication system||Installed both capacitance plates, Ohmed them out to insure and confirmed there was no ground and proper connections.
Pro sealed wires in-place tank is ready for close up.
|2013-06-16||Pg 20-1 Gretz Pitot Tube and Mount||Well I decided to use the Gretz Automatic heat controlled Pitot Tube instead of the Vans Bent tube design.
Started the Gretz Pitot tube mount installation. It has you add a support and a doubler plate to the bottom of the left wing 1 bay outboard to the last inspection panel at the aileron bell crank
I fabricated a angle bracket and fit it to the outer side of the rib, to support the doubler plate and the wing skin.
Deburred all parts and primered as needed.
Riveted angle support to wing rib.
Ran plastic conduit down thru both wing ribs for all electrical wiring. Ran stall warning wires thru conduit and secured to rib with plastic clamps
Trimmed and fit Gretz pitot tube to fit tub to mast.
|2013-06-22||Pg 18-8 Rt Fuel tank aft Baffel||Step1 Apply sealant just forward of the thank baffle rivet line no larger then 3/16.
Seal the most outboard and inboard rib flanges and corners really good to prevent a leak.
Seal the aft flanges on all other ribs
Install tank baffle into tank by dropping straight down cleco each rivet hole in the aft flange and all rivet flange holes
Let sit and cure for a few days
|2013-06-22||Sec 20 Continue setting up the Pitot tube||Rivet nut plates to pitot tube mast|
|2013-06-23||Pg 18-8 Rt Feul Tank Aft baffle riveting||Step 2 Install rivets attaching the tank aft baffle to the thank rib aft flanges
Step 3 Apply pro seal to the face of the tank Z brackets and cleco in place
Swirl pulled rivets in pro seal prior to installing. Install Z brackets with pulled rivets
|2013-07-12||Pg 18-8 Rt Tanks aft baffle riveting||Step 4 Rivet aft baffle to tank skins, these rivets are shot dry.
Step 5 Install fuel cap
|2013-07-13||Rt Fuel tank Leak test after sitting to cure||I let the Rt fuel tank cure for over 2 weeks prior to leak testing.
24 hour leak test good. Left balloon on for 3 days and it did not deflate.
|2013-07-17||Sec 20 Pitot Installation||Made mount for pitot heat circuit board
Installed nut plates to the mount so it is removable from rib
|2013-08-03||Sec 18 Preped and primered fuel tanks||Scuffed, cleaned and primered all inner surfaces of both fuel tanks
Prior to installing them onto the wings.
|2013-08-10||Sec 18 Prep for tank mounting to wings||Found the wing spar countersinks were not deep enough for a #8 screw.
Countersunk all the screw holes in top and bottom wing spars on both wings to accept a #8 screw dimple
Re-primed all wing spars and counter sinks as needed.
Pg 18-8 Step 6 Installed Rt fuel tank to the Rt wing
Torched all spar attach bolts to 30 inch Lbs.
|2013-08-24||Sec 18||Fixed incorrect countersinks on the lt wing flanges
Finished installing Lt Fuel tank
Need to fix the fuel tank skin aft edge due to wing skins length
Shaved down tank skin aft edge so tank would it nice and flat and smooth transition with wing skins
Had to remove the tanks and fix the o/b skin to leading edge skin distance and shave the fuel tank skins to it would fit flush when installed.
Checked Rt tank Had to fix a small part of the tank aft edge but was able to do this with out removing the tank
Pg 18-8 Step 6 Installed the Lt tank to the left wing and torched spar to z bracket bolts to 30 in lbs
|2013-08-25||Pg 20-4 Step 1 aft spar gap seals||Step 1 Mark and fabricate Gap seal stiffeners
Step 3 Cleco gap seals to the rear spar on both wings
|2013-08-25||Pg 20-4 Install wiring and conduits in wings||Pre ran wiring in both for
Langing Lights and HID Power supply
Roll Trim servo
Marker Beacon on the rt wing tip
AOA Sensing tube.
Labeled all wiring at both ends
Ran wire for Roll auto trim from roll ap servo to wing root
and from roll servo to wing root
Had to order more wire for ap roll servo Power, and Can Bus wires.
|2013-08-26||Finished installing Lt wing fuel tank completly||Finished shaving the top edge of Lt tank and installed screws now tank fits perfectly flush and looks great
Finished the Rt tank top edge and reinstalled the screws and not if fits nice and flush also and looks great.
Fuel tanks are now Finished completely
|2013-08-30||Pg 20-3 Lt wing gap seal||Step 3 Final drill Lt wing gap seal
Step 5 remove gap seal, deburr ll edges and drilled holes
De-burr top skin holes top ad bottom
|2013-09-05||Gap Seals Diple and Priming||Scuffed gap seals and gap stiffeners
washed and primed both wings gap seals
Counter sank for #4 rivet on the most inboard 6 rivets
Riveted gap sea; stiffeners to inboard side of gap seal.
Cleco gap seal to rear spar, and aft holes in the top skin
Started to rivet the 6 inboard #4 rivets
|2013-09-08||Rt Wing Gap Seal||Final Drilled all # 40 and 330 holes
Final drilled Flap gap seal stiffeners
Removed gap seal and deburred gap seal. and all rivet holes and rear spar.
|2013-09-15||Rivet Left Wing Gap seal||Rivet Lt wing Gap seal to aft spar and top skin.|
|2013-09-15||Rivet RT wing Gap Seal||Riveted Gap seal to rt wing aft spar and top skins.|
|2013-09-29||Pre Wire wings for lighting, and accessories||Installed wiring for Roll trim left wing, AP servo RT wing, and AOA Tubing.|
|2013-09-29||Install j stringers to Both wing bottom skins.||Insert j stringers to lt wing. Cleco inboard bottom skin to both wings.
Found Lt Wing J stringers fit nicely
Found Rt wing J stringers were moss drilled by previous owner.
Will order new J stringers from Vans tomorrow.
|2013-10-05||LT Wing J Stringers||Cut new Lt wing J stringers inboard and out board.
Drew 5/16 line for Center line.
Inserted j stringers into Lt wing
Started to match drill j stinger to bottom skin.
|2013-10-05||Pitot Tube Mast||Clecoed pitot tube mast doubler to the outside of outboard skin.
located in the 3rd bay next to the most outboard access panel opening.
Started to cut out center hold for pitot mast in the outboard skin.
Them the 20 plus year old dremal tool burned up, sparks flew and then it quit running.
Time for a new one.
|2013-10-12||Pitot Tube Mast||Finished cutting hole in bottom wing skin.
Final drilled all rivet holes in doubler to bottom wing skin
|2013-10-12||Lt Wing Bottom Skins and J Stringers||Final drilled all rivet holes in lt bottom wing to J stringer
Found both inboard and out board skins are a tad long. Need to shave the fwd skin edge down just a bit to allow a perfect fit.
Finished clecoing Rt wing bottom skins to Rt wing
Final drilled J stringer to bottom skins.
|2013-10-13||Lt Wing Bottom Skins triming||Removed bottom skin from wing
Trimmed 1/32 from forward edge of both inboard and outboard skins
Skins now fit well.
Re clecoed skins back onto the Lt wing.
|2013-11-02||Lt Wing Bottom Skins Final Drilling||Final drilled all lt Wing bottom skins to lt wing.
Final drill #19 screw holds on lt wing inboard bottom skin.
Final Drill nutplate rivet attachment holes on inboard bottom skin.
|2013-11-02||Rt Wing Bottom Skin trimming and final drill||Removed Rt wing bottom skins to trim forward edge.
Shaved off 3/64 off the forward edge on both rt wing bottom skins.
Re clecoed skins back on to wings, final drilled bottom skind to rt wing. Finished about half the wing. Will finish tomorrow.
|2013-11-03||Rt Wing Bottom Skin final drill||Finished final drilling Rt wing bottom skins.
Final drilled #19 screw ho;ls in inboard wing skin
Final drilled nutplate rivet holes in inboard skin
|2013-11-03||Ran wiring for OAT temp probe||Ran a 3 wire shielded wire to rt winf Inboard access panel area for the OAT Temp Probe.|
|2013-11-03||Lt Bottom Skin lapjoint||modified both Lt wing skin lap join skin over lays.
Feathered edged on that skins to make a nice a smooth lap joint.
|2013-11-25||Replace damaged rt wing outboard j stringer||Garage Door destroyed rt wing outboard J stringer
I cut new one and final drilled j stringer to Rt wing outboard wing skins.
|2014-01-01||Tested new Pitot Tube||Tested new Garmin heated Pitot Tube
Man does this thing get hot quick.
Determined on how i want the control box mounted to wing.
I need to install 3 ea #6 nutplates
|2014-01-01||Lt Wing Bottom Skin Lap joints||Finished up both left wing bottom skin lap joints|
|2014-01-11||Pitot Tube Heat control box mount||Worked on pitot heat control box mounting location and wire runs.
Trimmed pitot tube pressure and aoa air tubes to fit wing.
Final drilled holes to mount control box
|2014-01-12||Pitot Control Box||Finished making and mounting Pitot Control Box in outboard Left Wing.|
|2014-02-09||Aileron Trim Serveo Kit||Built Lt wing Aileron Trim Servo mount kit, and preped for wiring.|
|2014-02-16||Left Wing Trim Servo||Wired the Lt Wing roll trim servo
VPX Trim power white -------------- Rt wing Ap Servo in Pin 11
VPX Trim power White -------------- Rt Wing AP Servo in Pin 12
i-------------Rt Wing AP Servo out Pin 13
Roll trim power pin 1--
i-------------RT Wing Ap Servo out Pin 14
Roll trim power pin 2--
Roll trim power pin 3 --------------VPX Trim Ind orange/white
Roll trim power pin 4 --------------VPX Trim Ind Green/white
Roll trim power pin 5 --------------VPX Trim Ind Blue/while
Roll trim power pin 7 Shielding to Ground
|2014-05-05||Lt Wing Trim Servo||Wired up CPC connector for Wing trim Servo
Pin 1 White power from VPX thru AP Servo
Pin 2 White Power From VPX thru Ap servo
Pin 3 w/orange Servo Trim Indication to VPX
Pin 4 w/green Servo Trim Indication to VPX
Pin 5 w/blue Servo Trim Indication to VPX
Pin 7 Ground not used by servo
Servo Wiring completed in wings