September 22-25, 2016: Rudder Section 7

Catching up on where I am today.

On September 22nd, I continued prep of parts for Section 7 - lots of deburring and some dimpling.

On September 24th, Completed Section 7, page 3 steps 2-4.  Completed Section 7-4.

September 25th:  primed parts for assembly of the rudder spar, completed Section 7-5.  Problem with one rivet on lower spar - had to drill out x 2.  Finally ended up with a "good" rivet but it was a 4-8 instead of a 4-9.  The rivet head was a little on the small side.  Contacted Van's support - "build on".

September 21, 2016: Continuing on Vertical Stabilizer

The replacement parts arrived yesterday.  I spent some time yesterday prepping the replacement parts (cleco to matching parts, drill/deburr).  Then dimpled, prepped and primed parts for the VS skeleton (ribs, rear spar and doubler.

Early this morning I primed the mating surfaces of the VS skin.  Later, with help from Kathy, I dimpled the skin using the DRDT-2 and Cleaveland dimple dies.  Then mated the VS skeleton (starting with ribs and front spar), riveted the front spar to ribs, and clecoed this assembly to the VS skin.  Then riveted the skin to the skeleton.  After completing the internal rivets and more forward rivets to upper/lower ribs I clecoed the rear spar to the assembly, clecoed the skin to the rear spar, and completed riveting the entire VS structure.  Missed one skin rivet (I think we put in place and it fell out after we missed it and after the rear spar was riveted in place.  Did research on this and placed a blind rivet (countersunk) in its place - looks good except for mandrel hole which will get filled later and painted over.    One other error - where the two lower ribs join the front spar I was unhappy with 2 of the 3 rivets.   Drilled them out and tried again - results "OK" but I wasn't comfortable with the outcome.  So I drilled a hole between these two and placed a pop rivet.  A bit of overkill perhaps but I'm comfortable with this solution.

Vertical Stabilizer - Skeleton assembly, first part re-ordered

Yesterday spent about 6 hours total doing prep of the skeleton parts of the VS.  Lots of deburring and drilling (not in that order).   Pre-assembled the skeleton and skin, test fit and match/final drilling.  Dimpled the skeleton parts.

I did make two mistakes:  On the lower rudder hinges I drilled #12 one hole each that should have been match-drilled #30 to the main VS spar.  New parts ordered.   I also over-trimmed for skin fit the VS-705 nose rib - there wasn't enough material to match drill the forward-most hole.  New part ordered.  I will flute the front of this part to help the skin fit and limit the material I remove.  I probably could have gotten by in both cases by drilling riveting other holes in the first instance and just "building on" in the second.  But I want to develop the habit of doing everything as "by the book" as possible.

Today - 2.5 hours prepping parts for the rudder assembly.  

Kit Arrives. Starting Section 6 Vertical Stabilizer

Kit arrived on September 16th.  Kathy helped me inventory and put away the contents.  Only a few minor missing items - some backordered and a few minor small parts missing.  I emailed Van's and they will send the missing parts.  Today I finished the first page of section 6 - basically fabricated the front spar for the vertical stabilizer.  Using PVC, plastic sheeting, and "plastic hardware cloth" I built a paint table that allows me to prime parts outside (may use in the garage with door open - if so will wear full respirator and protective gear).  For now I'm using SEM primer. About 3 hours of build time today.

Synergy Air Fundamentals Class

I attended Synergy Air's fundamentals class on September 10th.  Completed a practice project.  This was a very good learning experience, well worth the time and travel.  I feel much more confident to start the project now.  Will do some more practice stuff before riveting on the actual kit.

Shop Setup

Empennage Kit ordered 1 September 2016.  Shipment expected to arrive sometime week of September 12.

Workshop has been set up for a few days.  A few photos below.  It's much different already.  I've moved things around, added some hardware bins, and connected the compressor to lines that have multiple outlets for tools/sprayer etc.

Tools on order from PlaneTools.com.  Should arrive today.  Lots of other tools and supplies on hand and ordered from Amazon, Cleaveland Aircraft Tools, and the aviation departments of Lowes and Home Depot.

Starting my 14A build log.  Nothing fancy here.  Just using this to document the process.  Here's a cutaway view of the RV-14A: