Category: RV10

RV10 Build Project

Wingtips – Flyleds – Part 1

Brian 0 Comment Wing Tip

With cold weather outside limiting my ability to prime parts, I continue to find things I can get done to make forward progress. For about a month I have been wanting to build my Flyleds works kit but it didn’t make sense to install the electronics until the boards were sanded to their final shape.

With the wing tips moved out of storage, I started with marking the cutout shape based on the template provided by Flyleds. I then quickly cut out the excess material with my multi-tool (This is the perfect tool for cutting fiberglass!). With the basic shape cut out, I install the boards and mark where I need to trim the circuit board / wingtip so everything fits. Initially I manually start sanding as I didn’t want to break the circuitboard on my belt-sander, but then realized I was just making my life difficult for myself. A Beltsander is the perfect way to quickly trim the Flyleds.

Off-camera I solder on all the components and test that everything lights up as expected (using a 9v battery). With those test completed, I bring the board back out again and mark where the wing-tip needs additional trimming due to the heatsinks. I then go to do the same on the other wing-tip.

Only difference is the other wing-tip had some voids under the gelcoat that needed a little touch-up. I sanded everything around the void to make sure I had a good bonding surface and found the void was even bigger than I first realized. No big deal. I had some Evercoat skim-coat on-hand and quickly mixed up a batch, applied it and used a scraper to help give it a rough shape. Came back after dinner and it was ready to sand / clean up. I then just did the same process as the other wingtip. Only thing left to do is drill the holes for the nutplates to mount the FlyLeds to the wing-tip and bench-test everything.

Ailerons – Part 1

Brian 0 Comment Ailerons

Starting section 21 I start to read through the instructions and pull the parts from storage. The language in section 21 starts to change from how the steps are defined in previous chapters a bit so I wanted to mention how I approached it.

Typically you see instructions to flute ribs, cleco together, match drill, then deburr, dimple and if desired prime. For the ailerons, instructions start with flue, final-drill, and dimple before you assemble anything. As I typically dimple after I prime parts, I’m having to deviate from the order of operation in the plans just a bit. (Not that this is a bad thing as I go on to explain).

Since I want to prime parts, then dimple, I’m “skipping” over the areas where I’m asked to dimple or rivet and assembling all the parts using clecos to ensure I can match/final-drill where necessary and that I have all the parts properly marked / labeled. I basically ended up building the whole aileron using clecos. *Note: cutting, sanding, and deburring all the stiffeners was a bit of a process!

I’m not sure if the change from match drilling to “final-drill” is due to better tolerances in the MFG processes for the skin and stiffeners, but I decided to match drill and label all parts.

With all the ailerons assembled with clecos, match drilled and deburred, now I just have to wait for a decent day to prime before I can start begin final assembly.

Fuel Tank – Part 5

Brian 2 Comments Fuel Tanks

Ok, so I’m officially sick and tired of proseal. With that said, I’m walking away from it for a few months before I finish up the fuel tanks.

With that said, I now have two mostly completed fuel tanks and once all the pro-seal cures, I can begin leak testing. I’m going to give the tanks a few months so that I have warmer weather before I start leak testing. (Honestly that is an excuse so I don’t have to mix any proseal for a bit).

I did my best to film the whole process this time as it takes MULTIPLE sessions to get this done. I bounced back and forth between wet-setting things in one session and allowing the proseal to set with the ribs fully clecoed in place. Also I had one LUCKY mistake when back-riveting the stiffeners. I did not mark or bend the skin, but drove the rivet into my table as I missed the backing plate.

I also started to rivet the ribs in the wrong order, but caught myself and only had to clean up a little proseal. Not a huge deal and I’m sure if I did install that rib first it would have been fine.

Lastly I realized I installed the fuel vent line incorrectly on my right tank. I missed there are two sets of holes that you can use to run the fuel vent line. The one closest to the nose is the correct one and makes life so much easier. The other set of holes is for the fuel to get to the fuel pickup. I have a feeling I’ll need to “fix” my right wing before I seal it up. (will also need to muck with my fuel float again. GROAN!). Not an impossible fix but have to think it though. EDIT: no dummy, fuel vent is on the top of the wing. I’ll still have to look to see if there is any good reason to re-route the vent line before I seal up the tank. Currently leaning towards leaving it alone.

I’m also really happy with my ductless mini-split system. With almost 8″ of snow outside I was still able to finish up my fuel tank in a t-shirt and be quite comfortable. Anyway, now it’s time to clean up the shop and get the flaps and ailerons before the fuselage shows up!

Fuel Tanks – Part 4

Brian 0 Comment Fuel Tanks

With the fuselage on order and a deadline to get the garage ready, time to get into gear and make progress. Granted we are now in prime holiday season and family is the higher priority over building, so this it’s more of the same get a few mins here and there to keep making progress.

Decided to bundle all of the prep for the right tank into a single video even if that made for a slightly longer wait / longer timelapse. Nothing special or different from the left tank. Deburr edges, install the structure and match drill. once fully assembled, take it all apart and start deburring.

I did make updated tank / leading edge cradle based on the plans finally. It did help a little with getting the ribs to line up. (also needed another cradle anyway).

Got all the parts dimpled and ready to begin final assembly. The only thing I did slightly differently was I didn’t install the nutplates for the Zee’s yet as I’m still deciding on if / how I’m going to prime the tank. I also am waiting to mount any of the shims to the tank attach bracket until I decide on priming. (after I leak test the tank).

Just like the left tank, I also installed a fuel return port. Slow but somewhat steady progress.

Fuselage and other items to order

Brian 0 Comment RV10

With the end of the year approaching and the wings not completely finished, I have been trying to determine when I needed to start ordering the next few pieces of my kit.  While I am a little behind on my personal schedule, I’m also need something to keep me motivated.  With that in mind, I finally decided to pull the trigger and order the Fuselage Kit.

Earlier this year (maybe in August or September) I heard that Paul at Approach Control was doing another batch of his pedals.  After trading a few e-mails with him, I was able to put down a deposit on a set of RV-10 Approach Control pedals.  The only issue was that since I didn’t have my fuselage kit, I didn’t have master cylinders to send him.  He was able to work with me and hold my pedals set until my fuselage was ordered / delivered.  He also sent me a list of items to remove from the kit that I wouldn’t need.

In addition to removing some of the pedal parts, I also removed the windows and winscreen from my order and will order a set of Cee Bailey windows (maybe later this summer).  Not sure if that was a great idea or not, but have heard good things about the Cee Bailey windows and ease of install.  

I also decided to add in a few extra stock items in my fuse order since I’m already getting a large box.  Some extra piano hinge for installing the wingtips, extra aluminum angle  “just in case”, and a few other smaller items. 

In addition I had ordered the FlyLeds “the works” kit a few weeks ago.  I didn’t remember getting a shipping notice and was very happy when I found the package at my door the other day.  This include the wingtip landing led lights so I’ll end up having both the duckworks and the FlyLed lights.  It may be overkill, but that’s what I’m doing.    

Now my biggest problem is physical space in my garage and what needs to move or get completed so I’ll be ready when the truck shows up with the fuselage!  Nothing like a deadline to get you motivated, right?

UPDATE: I had also ordered the flap position system, however I realized after that this is not needed if you are going with a G3X and GAD27 system (built-in!). Looks like I have to return my first part to Vans 🙁 Already have the Ray Allen POS-12 on order to make it all work!