Visit to Vans

On our way to cannon beach for a wedding, Bekah agreed to stopping in at Van's.  Couldn't justify being that close to Vans without making a quick visit.   I was able to pick up some parts I needed and a couple will call orders from others in my EAA chapter, but most importantly, Bekah got her first ride in an RV..   I told her this would help her "understand" and even bring out the RV Grin..   It did, she had the best flight and now is re-energized as to what is going on in our garage.   

Also throwing in a couple pics of Cannon Beach..  Just amazing..

Fuselage Organization

Now that I have all this metal and small parts associated with the Fuselage kit, I am trying to get organized so I can be productive.   I hope to make some shelves out of the wood box that the kit came in.  Also, I have bought some organizers and am able to put the bags in them labeled appropriately so there will be no confusion down the road.   Hopefully by end of week I will be ready to go.  I will post pics as I get the opportunity.

Misc Stuff

OK, no pictures, but I have been making progress. I have match drilled the left wing spars to ribs and pulled the assembly back apart deburred and am now prepping those ribs for priming. Also, been working on the shop a bit, have the right wing skeleton hanging in the stand waiting for the match drilling. Hopefully will get to that tonight and take some photos.

Also working on jacks to support the center of the wing since it sags a bit in the stands, and as well am creating dunk baths for the aluminprep/alodine process that I plan to put the ribs through. For those Purists out there I am working on a assembly line type of bath system that might be pretty cool. Here is hopin.. Either way, will go with the PPG Epoxy primer on the ribs because its pretty and also seems to be lighter than the rattle can.. Pretty soon my technicolor wing skeleton is going to be looking good.

Also I had a friend pick up some parts from Vans. I got the Deluxe fuel caps, a flop tube, wing conduit, and the right wing tie down which I have been waiting for. Now I can get the wings back to the same point. Want to keep them at the same stage as much as I can.

Shop Prep / Starting the Spars

Today was a huge day of progress. I was able to get the shop 100% into Shape for the wings. and even got started on countersinking the spars to prep for the nut plates that hold on the tank.

First a few things around the shop. The wing jig is complete and I used wood from the crates to help strengthen and as well provide locations for storage of items up high. I didn't want to drill into the concrete so I used some RTV (all I had was high temp, but oh well) to seal the bottom of the posts to the concrete.. It dried pretty stout and I dont think I will have a problem cleaning it up when done.

Also, I used plywood to create a pocket for the skins on the garage wall. Works for now anyway. I was able to use almost all of the crate material around the shop, saving a bit of cash, but more importantly reducing having to get rid of the stuff.. At least for now.

Found some time in the middle of everything to prime all the plate nuts as well as the aileron counter weights. Used Rattle can, and was really no problem, but tons of plate nuts.

The big event for the day was actually starting the spar prep. I had to predrill, then machine countersink for the nut plate attach rivets. Using Electrician's tape keeps the shavings out of the spar and won't leave residue on the anodized surface like most other tape. I haven't countersinked for the #8 screws yet but will save that for tomorrow.

Wing Inventory Day

Long weekend so we are hoping to get a lot done. Today we were able to inventory the entire wing kit and try to find a location for everything. There were tons of rivets, tons of ribs and a lot of Misc hardware. Did I say how pretty those spars are ?

Also started the wing jig and am going to build both at once so decided to use two separate supports so I can walk between the wings. Tomorrow I will build out quite a bit more on the jig and leverage the supports to hold some items up high getting them out of my way.

I used some of the crating material to make a shelf in the garage that will only hold light weight items, but perfect for the wing tips.. Also, some of the aileron/flap skins..

Reserved 704CH

Bekah and I have settled on our N number and I reserved it with the FAA. This step gives more reality to the airplane and kind of gives it a name in a way...

"Experimental 704 Charlie Hotel" OR "RV 704 Charlie Hotel" Sounds even better don't you think?

!

Priming/Dimpling Horizontal Stabilizer

So first off I went to the EAA Sport Air Workshop all weekend and found it pretty helpful, although it was really aimed at someone who hadn't even started building yet. I was able to get a few key questions in which made it worth it. Also, meeting other people who share the same interests, and getting a few emails to bounce ideas off etc, will end up helping in the long run.





Best part of the weekend was that a local builder gave me a pre-built DRDT 2 Dimpler table. Its great, and fits perfect. Allowed me to dimple the rest of my skin in a matter of minutes. Check out the pics, a solid table like this is really the way to go. Thanks Rob ! !















Also, I tried my first attempt at "metal prep" and priming. Wow, this is tough. first Scotchbright, then Alumiprep, then Alodine. I found that using Scotchbright with Alumiprep at the same time is messy and gets it all over. This stuff is unhealthy so you want to keep it as clean as you can. So going forward this is what I am going to try:





1) Rough the part with Scotchbright, easy and quick process.


2) Dunk in bath of, or wipe down with Alumiprep in a rag to clean off oil/dust, and etch the metal. Use gloves and keep the Alumiprep mixed in a sealed container.


3) Wash after with Water.


4) Dunk the part in Alodine (mixed with water), or paint with straight Alodine if the part is too big to dunk. This will provide better adhesion of primer and additional corrosion protection. (The Alodine step is not absolutely necessary so might be skipping this one in the future.)


5)Wash with Water, Then Prime.


I use gloves and safety glasses through this whole process. Here are some pics at my first attempt at priming. Need more reducer, it went on kind of clumpy. (not too good)

EAA Sport Air Workshop

I signed up for the weekend long RV Builders workshop this weekend up in Arlington. Bummed because it will be a whole weekend that I can't work on the plane, but in the long run it will be worth it, looking to meet other RV builders as well as hopefully learn tons that will speed things up down the road.

Last night I worked on the right stabilizer to catch it up to the left side. Everything is going well at this point, will get some pics tonight and post my progress.

Additional Fixtures

Today I did more work on getting everything built out so that later on down the road things will go faster. I built my "press brake" for bending the Elevator skins, and as well built out my priming table. Still not 100% sure how I will prime, but I am getting closer to figuring it out and do know that I will use a table such as the one in this pic. Also, I am building a table for the DRDT-2 Dimpler, but using my own design and hoping for the best. If it works, I will do another write up on it in a separate post, if not, you will probably never hear about it again. ;-)

Finally, the rest of my tools

Today, over 6 weeks from the initial order, I finally got my "swivel flush rivet set" from Avery. Not happy with them, but it did finally come, so I could finish my practice projects. Liking the way the flush rivet set works, much easier than the standard round head rivet set. I still have more work to do, but am getting along pretty well with it.

Continued Progress

Going slow but having fun and liking how this aluminum stuff goes together. I am almost done with the practice project and decided I need to order another as well. It seems pretty straight forward but I do want to make sure I try everything a few different ways before attempting the real thing. Also, I haven't quite got the primer thing figured out yet so another week or two and I should have it all in place and ready to go.

My First Rivets ! !

OK, so I decided to take a crack at the practice project tool box from Van's. As you can see I squeezed my first ever rivets and they turned out OK. A few lessons learned though about how soft aluminum is and that it scratches way to easy, so will need to take greater care when riveting the actual airplane, but I think for a first time I did pretty well. I only used the squeezer and the dimpler so far.. My flat head rivet set for the gun is on back order so won't get that for a few days yet. I am concerned about the circles around the countersinks but don't think there is any way to avoid them no matter how good a riveter you are, as well I was confused with the pneumatic squeezer as I think I was forced to use it backwards and will need to use it backwards for most areas on the airplane.. It is tricky using it backwards and the directions say not to, but I think you will have to at times. I will ask the pros next time I get a chance.



Oh, also loading a pic of the shop.. Lights are up, table covered etc.. Ready to go..

Avery RV Builders Kit Arrives

Today I got the rest of the tools from Avery for the RV builders kit. It looks like it has everything I might need and then some. Its funny how the tool might be so similar to a normal Hardware store tool, but because it is aviation related it just costs more. Seeing the tools, I think I could have gotten away with buying a few locally for cheaper. But I didn't know that to begin and this kit does come with everything in a one stop shop, so for that I am happy. Most of these tools are specific for aircraft. Can't wait to start using them. I haven't even ordered the empanage kit yet from Vans.. Better get on that.

Do you see the pneumatic squeezer? Worth its weight in gold.. ;-)

The DRDT-2 Dimpler Arrives ! !

OK, here is a cool tool.. This guys whole purpose is to dimple the skins so that the rivets will fit into the countersink. Its a fairly high quality tool, nice powder coat and unlike the normal dimplers, doesn't use a hammer to strike the dimple piston. So its quiet, I can dimple all night long. Got this through Avery tools by substituting out other items. Can't wait for the next batch of tools to come.. Will include my 4K Drill and the Pneumatic Squeezer.. ooh.. can't wait.. ;-)

EAA Work Tables - Complete

Just finished the work tables and now my shop is 90% complete. Just a bit more organizing and some more light, but I think we are close. Next step is to check out the tools that come later this week and work on a practice project.. Vans sells an aluminum tool box that you build in order to practice smacking rivets.

Before making an aluminum airplane, you need to practice a bit so that the first rivets on the plane are as good as the last.

Building EAA work Tables - First real task

Here we are building the work tables. Leveraging the nice weather and help from the brother inlaw visiting from Alaska. We kocked these out pretty quick and were fairly happy with the results. Plans are available by Googling EAA standardized work tables.

Bekah took the time to draw me a picture of the day of the first flight. Long way away from today, but as you can see it is a successful first flight and I am giving her the Hi Five and the RV Grin.. ;-)

Engine Choice

Engine choice is a major decision as part of building an airplane.  Its really one of the most expensive and most important parts of the finished airplane.  For RV-7's the engine pretty much has to be the Lycoming style 4 cylinder engine.  There are many options that the builder must determine though starting with Horsepower..   ;-)   Also, ignition type, aspiration type, injection, sump type, etc..    I won't go into all the details, but I chose to buy new, non-certified.  Basically built the same as certified, but less government mandated paperwork, so it is less expensive.   Realistically there probably isn't any safety difference either, and the engine is warranted for 3 years which isn't typically the case with a new certified Lycoming.. 

The engine I ordered is about the highest end engine for the RV, outside of the 390's or the 200 hp angle valved engines.   Its a high end, high horsepower (195 hp), mid sized (360 sized) engine..  With this engine and prop combination that I am going with, as quoted by Larry Vetterman, I won't be "tail end Charlie"...

I chose to go through Aero Sport Power up in Canada.. They go a great job and have many good recommendations..  Plus I met the owners Bart and Sue both at Arlington fly in and Oshkosh fly in last summer..

A final thing to consider is fuel..  Avgas is 100LL and there may be changes to this over the next few years..  The engine I bought has low compression cylinders which allow for lower octane fuel such as premium auto fuel.. (but it can't use ethanol)..   So with this engine I should be safe with what ever future fuel is used for aviation engines..

Below are the Specs:

Aero Sport Power Ltd. New IO-375 (195 HP) Horizontal Induction Engine Includes:

Superior Cylinders with standard 8.0 to 1 compression ratio, One Slick Magneto and Harness with Light speed Plasma II + Crank Triggered Electronic Ignition, Spark Plugs, Sky-Tec Light Weight Inline Starter, Plane Power 60 Amp Alternator, Precision Silver Hawk Fuel Injection, Fuel Pump, Camshaft and Lifters, Superior Cold Air Horizontal Induction Sump, Connecting Rods, ECI Crankshaft, Dynafocal Type 1 Crankcase, Ring Gear, Inner Cylinder Baffles, Dipstick and Tube, 90 Degree Spin on Oil Filter Adapter and Vacuum Pump Adapter Housing.  Engine to be painted yellow, cylinder black bases and gold alodined fins.  Inverted oil modifications.

Constant Speed (M1S) Outright

Using Superior Components with Roller Lifters

Here is a pic of one of their recent engines..   Mine will be Yellow where this one is Red, plus this one has two mags where mine will have one mag and one lightspeed electric ignition, also mine will be fuel injected.  But in general it will look like this one.