Empennage

Aft Fuselage (3 hrs )

Sect 10-12, Steps 4, 6-8:  Dimpled Bulkhead for nutplates (2 types).  Scuff, clean, and primed Bellcrank Ribs and Bulkhead.  Riveted Battery Angles onto Bellcrank Ribs, then nutplates onto Bulkhead, and finally riveted into sub-assembly.

Pic below shows 2 washers added to die on Main Squeeze to clear flange just enough.  Fully retracted movable end with Universal head, so that was really close to having to use rivet gun.

Empennage

Aft Fuselage ( 2.5 hrs )

Sect 10-11, Steps 6 & 8:  Machine countersunk Battery Angles for flush rivets to retain nutplates - then riveted on the nutplates.    note:  2 are are different #/size thd.   (also 2 locations are NOT used as in RV10 on same parts).
Sect 10-12  - Separated and deburred all edges on Bellcrank Ribs.  Deburred edges on F01406B Bulkhead.  Cleco'd Bellcrank Ribs & Battery Angles together to Final Drill #30 holes.   Dimpled flanges for Battery Bulkhead also.

Pic below is mock up assembly prior to scuff, clean, prime...   Still some more dimples and nutplates on bulkhead.

Empennage

Thursday,   May 25, 2016
Aft Fuselage (4.5 hrs )

Sect 10-11 Steps 2-5:  Finished deburring -  geesh, there's a lot of edges due to slots for longerons, etc plus many lightening holes.  Repeated scuff, clean w/ acetone, and spray Primer 7220 (Napa brand). Riveted bulkheads.  Mostly completed Battery Angles steps to add nutplates on same section.

Empennage

Aft Fuselage (2.5 hrs )

Sect 10-11, Steps 1 & 2:  worked on the two larger forward Bulkheads....doing all the #40 hole dimples around the flanges...with a few exceptions noted.

Lots of lightening holes which take time to smooth edges/deburr.   Tried various tools (eg  dremel to reach inside holes) but mostly the std 6" grinder w/ scotchbrite wheel.  Although instructions don't denote, I smoothed facets of flanges...just as prior bulkheads.  Finding a 4" belt /6" disc sander with fine grit paper works well for that step.

Also enlarged one hole to 5/8" hole w/ step drill...for bushing w/ wire routing.   Seems odd several similar 5/8" holes already pre-punched - must be busy work for builder wrt 51% rule...?

Empennage

Aft Fuselage  (3 hrs )

Cont'd Step 4 at Sect 10-10:  Drilled 1/4" holes in HS Attach bars on drill press.   Finished deburring, scuffed, cleaned and Primed all parts - especially those w/o Alclad.

 Riveted the 47 Universal head rivets (three sizes) using Main Squeeze.

"family" of three aft bulkheads

Empennage

Aft Fuselage (4 hrs )

Sect 10-9 Step 2-7 completed:  finished deburring edges, holes and smoothed flange facets.  Checked fit into Aft Bottom Skin... A-OK!  (no fluting needed ...bulkheads were already straight and fit well)

Also cleco'd rearmost Bulkhead w/ Tie Down Bracket into position on Aft Bottom Skin.  Also good fit.   (prior sub-assembly is already primed)

Dimpled the #40 and optional #27 holes for the flush screws installation later (ordered screws and nutplates from Van's today).  

  Riveted two H.S. Attach Brackets to these two bulkheads w/ 30 universal head size 4-7 rivets.  Appreciated using Main Squeeze again (needed to add 3 washers to lengthen reach of Universal die for flange height clearance).

Sect 10-10 Steps 1-3:  Next bulkhead sub-assembly includes "step drilling the 5/8" hole for bushing, dimpling #40 holes on flanges, deburring edges and holes, plus smoothing facets on flanges...again.    I prefer working each section (bulkhead sub-assembly) as mini-project following instructions in sequence, vs gathering all the bulkhead pieces and deburring, scuffing and priming as major batch.  With nice weather, set up outside to spray primer takes only a minute, so small batches are easy

Empennage

Aft Fuselage (1.5 hrs )

Riveted Tie Down Bracket to 2 Bulkheads 1412A & B in Sect 10-8, Step 2.   Able to use Main Squeeze, but only with a washer added to each die to clear flanges.   Perfect !

Much easier with Main Squeeze mounted to table...

Sect 10-9, Steps 1 & 2:  Cleco'd 1411A & B Bulkheads to HS Attach Bars, drilled #30 holes (lots for these key structural pieces).  Started to deburr edges...here I go again toward priming.   (with simpler spraying now outdoors, I'm closely following instructions vs working ahead to prime parts well in advance).

Empennage

Aft Fuselage (4.5 hrs)

Sect 10-5 Steps 2 & 3:  Drilled 17/64 Systems hole (several layers including steel VS hinge brackets) and Tie Down Bracket 4 holes at #12 size.

  Sect 10-6 Deburred edges, drilled holes, rounded flanges eliminating facets against skins.   Sect 10-7, Steps 1-3:  Lots of dimples in two bulkheads...sizes #30, #40, and #27 (#6 screw dimple dies works well).    With those completed, time to scuf, clean w/ Acetone, and Spray 7220 Self Etching Primer (Napa brand).   Ready to rivet !

Ready to Prime.  Parts on left are Not Alclad, so require Primer.

Empennage

Aft Fuselage ( 1.5 hrs )

Finished Sect 10-4, Step 2 Rudder Stop.  Almost overlooked Countersinking #30 holes at Step 3.  

Sect 10-5, Step 1:  Retrieved Vert Stab from "storage" room....fit up bulkheads with 2 cleco's  -  ready to match drill into VS rear spar.

 

Empennage

Aft Fuselage ( 1 hr )

Another beautiful Spring day - Sunny, 70 degrees, and only 4 mph winds....so went flying instead of building today.  Plus mowed yard, played tennis.  Thus only 1 hr in shop today.    Rudder Stops in Sect 10-4 are crazy shaped pieces !  Required extra caution to insure interpret cut dimensions correctly.   Note the isometric dwg above has parts "flipped" vs 2 view dwgs below.   Need new 18 pitch band saw blade...so only finished RH piece.

Empennage

Aft Fuselage  ( 2.5 hrs )

Sect 10-3 Finished deburring J-Stiffeners.  "Whacked" Horiz Stab Bars into flatness per Van's instructions.  Kinda tedious, but got them flat.   Then....deburred more edges.

Sect 10-4:  Measured really carefully  - then used band saw & 3M Scotchbrite wheel to create Horizontal Stab Attachment Bar Support Angle (ie HSABSA !) which is a long name for a 6" long angle.   Came out great....

Empennage

Aft Fuselage (3 hrs )

Sect 10-2 at Steps 2-6: separating J-Stiffeners, Battery Angles, etc.  Lots of edge deburring...  Then Sect 10-3 at Steps 1-3:  repeat for more J-Stiffeners, Longerons, Bulkhead Doublers.   Those Longerons are relatively thick, so edge deburring takes more time...and of course they're LONG, too.
No pics...nothing special yet.

Empennage

Elevator (1.5 hr )

Elevators are done !  (at least all of Sect 9 build)   Finished today the Molex connectors (geesh, these are tiny) for the Trim Servo.   Installed into Elevator following Steps 1-5 in Sect 9-25.   Powered up via 9 volt battery - to the white leads.  Reverse is simple switching  - and +  from battery.

didn't bother to switch ends for LH and RH for picture

Aft Fuselage

Aft Fuselage ( 1 hr )

Started Aft Fuselage, Sect 10-02.  Reviewed instructions, highlighting  Do Not ____'s ...and other noteworthy portions !    Gathered pieces to separate, etc.   Step 1 completed separating 2 plastic pieces into 8 short segments as Cable Guides.   Awkward dimensioning of dwg....vs other engrg dwg's that I'm used to, but I made it work anyway.  

Build time today cut short - I visited friend, Terry Moushon,  and his new RV10 to return his "RV10 bucking bar" used on my elevator.   He's just completed 4th one hour flight in his test program.   Terrific plane.

Empennage

Elevator (1 hr )

Counterweights installed (2 in LH, 2 in RH).  Torqued to 42 in-lbs (28 spec + 14 for friction of lock nut per Sect 5-20).  Installed Trim Tab, secured hinge pin w/ .032" safety wire ( I may redo w/ .041" safety wire...tbd)

 

Empennage

Elevator ( 2 hrs)

My brother and his wife visited this week from California...so no building Tues - Sat.  But lots of fun, including taking him flying for my first time.

Now on Sunday, back to building:  Rolled RH Elevator leading edges top and bottom skins.  Cleco'd, and ready to blind rivet.   Double checked top skin overlapped bottom skin.

broomstick used has convenient "nut" on end...easy to turn with wrench.

 Later during evening, returned to complete with blind rivets.   Looking good !

Empennage

Monday     May 9, 2016
Elevator  (2 hrs )

Sect 9-26 - worked on Counterweights to fit up properly.  Trimmed per instructions.   Another builder recommended using chisel to remove layer on backside (2 of 4 only).   It worked, but slow going on first piece.   While my bandsaw with small pitch teeth for metal bound up,  I discovered switching to all purpose larger pitch teeth worked really well to cut off the lead as needed.  Used wood rasp to level and trim to lines.

 

 

Rolled leading edges of LH elevator with help from my wife Nancy.  Cleco'd, so ready to do RH next.

Empennage

Elevators (2.5 hrs )

Nancy and I flew our flying club's C172 from Lacon (C75), Illinois to Effingham, Illinois (1H2) on Friday - just for fun.  Visited Mid-America Motorworks (free - w/ lots of Corvettes), and had a great lunch at the Firefly Grill.

So....I skipped building on Friday, but back at it Saturday.  Now with 3 days curing of the Foam Ribs (Tank Sealant/ProSeal ), did the final Root Ribs & Tip Ribs rivets.  Then the T.E. flush rivets using the "RV14 Safety Pin Squeezing Tool".   Tool is critical for reverse wedge on TE.

 

Empennage

Elevator  (2 hrs )

continued Sect 9-24 with Step 6-9 (after Priming cover and C Channel supports) for Pitch Trim Servo Assembly.   No "slop" in clevis pin to pushrod...a good fit.

Step 4 included Labels onto Trim Harness at each end, and trimming corners of Molex connector so fits through the bulkhead bushing.   Also applied silicone to seal end of Molex connector.

Empennage

Elevator  ( 1 hr )

Sect 9-24, Step 1 & 2:  Bent hinge pin to nest into channel at Inboard end of LH Elevator.  Relatively easy to bend this "wire" (vs piano wire I've used before on R/C planes which is heat treated and tends to break at sharp bends).  Drilled 1/16 inch hole adjacent...ready to safety wire once Trim Tab is actually installed.

Jumped ahead slightly to Step 5:  Pitch Trim Servo Assly.   For the #27 size holes, used #6 screw dimple dies (tested first with sample material same thickness...screw head fits well).  Then Countersink six  #40 holes that attach the support C-channels.  I first tested depth on sample material (0.032")...key since thinner material than typically countersunk.  Happy with results.

Empennage

Elevator ( 2 hrs )

Hooray !  Sect 9-23 Steps 1-10.  Successfully bonded all 8 Foam Ribs into LH and RH Elevators.  Added TE to each, using the double sided tape process.  Just cleco'd for now while "tank sealant" (Pro Seal) cures for couple days.  

Used lots of weight -everything but the kitchen sink on boards to compress top skin onto foam ribs and bottom skin.  Even used my C-Frame, and a few bricks too.

Empennage

Elevator  ( 2 hrs )

Sect 9-22 Steps 2-4 for LH Elevator - Outboard close out done.  Finished remaining Rear Spar rivets w/ RV10 bucking bar (those left open to enable lifting skin for outboard riveting access).  Last time I need this special bucking bar...but sure works great.  

I'm glad I recognized Skins go over Counterbalance Skins. (Van's has bold text statement in later page of the Elevator build...but key was knowing this during original assembly with clecos.  Good to read ahead ! )     Fit is "flush" - better than I'd anticipated with this overlap.

Empennage

Elevator  ( 2 hrs )

Sect 9-22 Steps 6-8:  Rh Elevator Outboard close out done.  Several different lengths of rivets kept me checking instructions frequently.    Two rivets are reached via lifting open the Skin and inserting the bucking bar inside.  

I found easiest to do with Elevator set as shown in picture below... instead of from bottom and top simultaneously.  

Finally got to squeeze in all the rivets along Front Spar on top and bottom.   Tomorrow I'll do the LH Close out.  Soon...bonding in Ribs and TE.