Empennage

Jan 7,  2016  (catching up in new builder's blog)

Vertical Stab  (3.5 hrs )

Sec 6-4  Step 6   Rivet Rear spar & hinges.    Great to see parts coming together.  Lots of different length and style rivets, but instructions are clear.  Surprised how much "grunt" takes to use Main Squeeze on the 1/8 inch rivets.   Lots of rivets, so got good exercise in arms.

Applying primer only to surfaces "scratched" during processing.  Trying to avoid excessive weight.  Some areas only receive light coat if Alclad is not been scratched.

Hole left open for Sec 10-05, 10-28, & 11-07.

Tape over some holes is temporary - until assembly with skin.

Sec 6-5 Step 1.   Assembled Front Spar. (no pics)  This simple step is challenging due to access to the rivets at angled flanges.   Worked through different set ups for each "joint" to enable proper access. 

Empennage

Jan 6, 2016  (catching up in new builder's log)

Vertical Stab (5 hrs)

Sec 6-4  Step 4 & 5.   Dimpled #40 holes in flanges of skeleton (ribs and spars).   Used Main Squeeze tool.   Set up drill press to use Micro Stop CS tool for #30 holes on Rear Spar doubler.   No pictures...but worked great.

Really careful to understand front and rear faces for dimple directions on Rear Spar (so will be flush facing forward !)

Prepped parts for priming by final scuffing, then clean thoroughly with Acetone.  Using good respirator - can't even smell the acetone or primer.

Empennage

Jan 5, 2016 (catching up in new builder's log)

Vertical Stab  (5.5 hrs)


Sec 6-4   Step 4.   Disassemble skin and skeleton to deburr, then scotchbrite, then dimple to be followed last by priming parts.

Note:  Contacted Van's tech support to clarify OK to Prime after Dimple if preferred (vs Dimple after Prime.  Concern was dimple process could "scratch" primed surfaces).   Also easier to scuff parts prior to dimpling to avoid need to scuff inside countersunk holes.

This established DDSDAP steps:  Drill, Deburr, Scotchbrite, Dimple, Acetone clean, and finally Prime.

C Frame reached all holes on skin.  Care to not overbend leading edge.

trial fit flush rivet.

Some holes taped to leave to later processing for fairing attachment.

Cleaned with Acetone.  Too late and tired to prime, since needed final touches on new spray booth.

Empennage / Shop Set Up

Jan 3, 2016  (catching up in new builder's log)

Build temporary/portable spray booth (5 hrs)

Needed spray booth to do priming of interior parts.  Too cold in winter in central Illinois to do outside, but with self-etching primer, really necessary to evacuate air.   Designed to fit into one of twin "man doors" in south wall of garage.

Built with hinges at all joints so can simply fold up both and store against nearby wall.  Used inexpensive 1x2's, 4mil visqueen (sp?), and lots of staples.   Installed 20 inch box fan to evacuate.
In middle, used old fencing section to hang misc components.

Works great !

Prior to installing fan at door, etc.

Inital test to try "folding" against wall.

1st parts ready to prime

Initial prime coat

Empennage

Jan 4, 2016 (catching up in new builder's log)

Vertical Stab (3.5 hrs)

Sec 6-4 Steps 1, 2 & 3: Cleco skin around skeleton after adjusting VS 706 & VS 705 fit leading edge.    

Per prior day, referencing Sec 6-3, I did couple iterations w/ caution to NOT remove too much material near rib web or holes.  

As noted in prior day's log,   Van's tech support confirmed this much removal is typical.

Final drill (using reamer)  #40 all holes , except  Match drill #40 four holes per instructions at nose and tip ribs.

Empennage

Jan 2, 2016  (catching up in new builder's log)

Vertical Stab (2.5 hrs)

Sec 6-3:   Rear Spar drill, deburr.    Used fluting pliers to slightly straighten VS 704 rib.

At step 5, I used scotchbite wheel to  "radius" forward ends of Nose and Tip ribs…as described in Sec 5.2.  

Note: Next day I repeated...Later, per note/instructions at beginning of  Sec 6-4  to not force fit skin around skeleton, I had to repeat process more aggressively.  Van's tech support confirmed this much removal is typical.

Empennage

Jan 1, 2016 (catching up in new builder's log)

Vertical Stab (0.5 hrs)



Vertical Stab Sec 6-2:  Rivet Front Spar & Doubler.   After primer dried for 24 hrs.

Empennage

Dec 31, 2015  (catching up in new builder's log)

Vertical Stab  (2.5 hrs )

And so...  The Build begins.
Start Sec 6-2  [Section 6 - page 2] , Steps 1 to 6:  Cleco, Drill, Deburr and Dimple.   Primed Front Spar and Doubler at their interface.

Don't have picture of parts just after prime but here's doubler riveted onto Front Spar in Vertical Stabilizer.
Duplicolor self etching primer is green.

Note:  After reviewing Van's recommendations, many builder's logs, and discussion with several local builders, I've decided to prime interior components "minimally".  ie ...at those surfaces with work affecting the Alclad coating (drilling, deburring, etc).  And of course all non-Alclad parts such as alum. angles.   I scuff w/ scotchbrite, clean with Acetone, then spray self etching primer.  Started with Duplicolor, but plan to switch to Napa 7220 or Sherwin Williams GPB 988.


Sec 6-3:  Scuffed powder coat on Hinges (prep for ultimate finish painting much later).  See Plan Gotcha's at Vans Airforce forum.   One of the ideas by other builders is to perform this action now, since harder to scuff for finish paint once hinges assembled permanently.

Hinges - in white - pre-scuffed (for later finish painting)

Empennage

Dec 19, 2015 (catching up in new builder log)

Empennage Organizing Inventory (6 hrs)

Counted specific items in all bags, and labeled each in drawers in parts organizers (2 of them !).  Lot's of practice using new Dynamo labeler, too.

Empennage

Dec 19, 2015  (catching up in new builder's log)

Inventory of Empennage Kit (5.0 hrs )

Full inventory of all 7 pages.   Beside two items on Backorder, found a few items shorted, and  one bag of misc parts missing.  Rec'd all on Jan 9, 2016.

Empennage

Dec 17, 2015 (catching up in new builder's log)

Empennage Delivery  (0.5 hrs)

No damage at delivery !    Old Dominion contacted me day prior.  Driver called 15 minutes before arrival.   He even brought crate into garage right where I wanted crate.

Practise Kits

Nov - Dec 2015 (catching up in new builder's log)

Ordered Vans RV Tool box kit for $28, and  RV Training Project - 1 for $35.  Great learning "tools"  -- to understand how to use the new tools, including air drill, rivet gun, squeezer, C Frame (to dimple),  and to follow Van's instructions...closely.   Each word is critical, so reading at least couple times really pays off.  

 Build project 1a first (above),  then Toolbox (below), then Project 1b (elev section) by end of December.

Countersink set up on drill press for trailing edge

reaching insider with tungsten bucking bar.  rivets on spar to skin

Specialized Tools

November 18, 2015 (catching up in new builder's log)

Ordered & rec'd from Cleaveland Aircraft Tool's the  Complete Airframe Pkg for RV14a.    After discussion w/ Mike Lauritsen, made a few minor deletions & selections.  Great customer service, and very good quality tools.  Especially like the "main squeeze" for dimpling & riveting.

Shop Set Up

Sept to December 2015 (catching up in new builder's log)

Converted 3rd stall in garage into "airplane factory".     Added 6 more fluorescent fixtures (to 2 existing).   Added (3) 1/4" pegboards floor to ceiling.    Installed 21 gallon compressor with filter/regulator and lines.   Electrician added additional circuit to accommodate portable electric heater.   Bought on sale: drill press, sander, grinder, band saw, vise.   Installed shelving on south wall.
Bought Craftsman tool chest as portable workbench/storage.

Dec 2 after adding fluorescent lights

Built 2 EAA workbenches with adjustable feet to level.  Added full width drawers to each for more tool storage (using left over plywood from lower shelve on each!).   Added supports between end of tables so the new C Frame is mounted at correct level.  Turnbuckles front and back allow easy removal and re-install.   Using old 2 ft wide rug on table tops...nearly perfect fit!