Category: RV10

RV10 Build Project

Outer Leading Edge – Part 9

Brian 0 Comment Outer Leading Edge

With my parents visiting for a few days, I had my father help me out a little. Got the right wing moved out of the cradle and clamped to my workbench and the leading edge clecoed onto the spar. Then got my dad to help me rivet on the leading edge.

As I was getting the rivets set, I identified a few rivets that I wanted to replace for one reason or another. I’m sure the rivets were ok, but it’s easy to replace in it’s current state. Also going back a few days or with a fresh set of eyes is always a good idea.

I finish up and replace the handful of rivets on the top skin, and rivet the leading edge ribs to the spar. We then shuffle the wing back into the cradle. This gets me in a much better place from a space perspective now that I shouldn’t need to remove the wings from the cradle until I get to the airport.

Outer Leading Edge – Part 8

Brian 0 Comment Landing Lights, Outer Leading Edge

Circling back to finish the landing light lens. With the experience on the other lens, I’m ended up cutting this lens to the “proper” dimensions this time. (The directions are correct even if you don’t think they are. Go figure!) Still debating if I will purchase a replacement lens for the right wing or not as the other does work just fine.

With the lens cut and fitted, I go ahead and mount the landing light in the wing (off camera) and struggle to figure out how to actually screw in the landing light lens as I can’t get behind it to apply any pressure. The lightbulb moment was when I realized I needed to use tape on the lens to help provide the outward pressure so I can screw in the lens.

With the lens installed (and protected by additional tape), I then got some assistance from my wife to cleco the leading edge to the wing spar. Getting the ribs clecoed into place I then begin riveting the leading edge to the spar. As a small note on the blind rivets, not sure if it’s just my blind rivet squeezer, but I really don’t like setting blind rivets.

With all the ribs riveted to the spar, I squeeze the skin rivets then ask my wife for assistance to rivet the top of the leading edge. Easy enough and once done I get to stand back and admire my progress. Plan on getting the other wing done shortly as I approach my fuselage crate date.

Wing Top Skin – Part 4

Brian 0 Comment Top Skins

Fairly short update, even if it was a lot of work. After prepping the wing and tops skins, started to rivet everything together. Started working with my wife using my new extended back rivet set. This left the skin looking great, but I kept having some rivets with smeared shop heads.

I even went and purchased a double-offset backrivet set, however I was even having some issues with that. I gave it a good try and it seemed to be somewhat working, but in the end I decided that just having my buddy and wife use the rivet gun and I control the bucking bar was much faster and easier to control. (Even if it did mark up the skins a little).

After each rivet session, I would go back the next day and re-check all the rivets with a fresh set of eyes. I would always find some marginal rivets that needed another hit with the bucking bar, or possibly a few that just needed to be drilled out. No biggie and better to do it now rather than when the wings are on the airplane! (Blue tape marks where I need to touch something up) [inpost_fancy thumb_width=”200″ thumb_height=”200″ post_id=”803″ thumb_margin_left=”0″ thumb_margin_bottom=”0″ thumb_border_radius=”2″ thumb_shadow=”0 1px 4px rgba(0, 0, 0, 0.2)” id=”” random=”0″ group=”0″ border=”” show_in_popup=”0″ album_cover=”” album_cover_width=”200″ album_cover_height=”200″ popup_width=”800″ popup_max_height=”600″ popup_title=”Gallery” type=”fancy”][/inpost_fancy]

Once all the rivets were in, I then riveted on the nutplates at the wing root, followed by the aileron bracket at the wing tip. Then with a little help from the wife I moved the wing back to the cradle. I’ll need to finish up the leading edge light lens for the left wing, then get some assistance to rivet the leading edges to the wings to make sure I have room for the fuse arrival.

Wing Top Skin – Part 3

Brian 0 Comment Top Skins

Finally jumping back to finish off the left wing. With a little assistance from my wife, we turn and move the wing to my workbench to begin prepping the skins for final assembly.

After deburring both the wing skins, I begin to deburr all the ribs. I ended up getting one of the “in and out” deburring tools online and used it for a good section of the wings. I’ll admit that it did a decent job without taking too much material off. I may use this for more of the build going forward.

I then move the wing so I can install the 4 rivets that I didn’t install earlier between the spar and ribs. I spoke about this in the previous post regarding the top skins as the plans were not clear on these rivets.

Next, I started to dimple the ribs, J-stiffeners, and the wing skins. Using the sawhorses, some 2×4 and felt mats allowed me to quickly get through the dimple process without any drama. I’m actually starting to get better working in the somewhat limited space I have.

I then mount the skins, J-channel, and wing-walk stiffeners onto the wings. Next I have to verify my countersink cutter is properly adjusted so I can countersink all the holes common with the wing-walk stiffeners. This makes a complete mess and lots of aluminum shavings!

Finally I take the time to mark anything longer than a 3.5 rivet on the skin so things will go faster once I get an assistant to help me rivet. I’m looking forward to using my new back-rivet sets to see if I get any better results vs the last time.

Air Conditioner

Brian 0 Comment Air Conditioner

So I have been going back and forth on this topic personally a lot over the last year or so. Initially I was of the opinion that this was a MUST for me for the comfort of my family. This has lead me to reading a number of blog entries from other builders on how they installed their systems and the different options out there.

Currently I’m following three systems (or two depending on how you look at it). Air-Flow systems, Flightline AC, and South Florida Sport Aviation (repackaged Air-Flow systems with overhead console). The Air-Flow / SF Sport Aviation system uses a condenser scoop that sits on the belly of the aircraft that looks like a P-51 scoop, while the Flightline system is contained in the tailcone just behind the baggage bulkhead.

I was personally thinking of going with the Air-Flow system package as I liked the idea of the condenser sitting outside of the aircraft. It looked slick and installation didn’t seem to be too challenging. It also didn’t have the issues of routing air for the condenser through the tailcone and freed up some space in the tail.

The downsides to all of this is that the AC is really only there to help on the ground, or down low on a really hot day. As I said I thought this was a MUST for my family, but starting to change my mind. In addition to it’s limited benefit, it is a complex system in general, with modifications needed Firewall forward, as well as in the fuselage. Extra hoses / cables that need to be routed, and additional weight to an aircraft. It is also an additional cost in time and budget.

As I submit my final payment for my fuselage and feel my bank account lighten, I am starting to plan out some of the additional items that I will need to order throughout the year for this project. Since an A/C is much easier to install when working on the fuse, this item is highly visible on my list of things that may need a decision in the near future. At the moment, I’m of the opinion that an AC is a luxury item that is not needed in my situation. With the exception of possibly going to Oshkosh, I shouldn’t be in a position where I will have an extended ground taxi in extreme heat / sun.