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  #1  
Old 08-23-2017, 09:47 PM
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Bullseye Bullseye is offline
 
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Location: Wichita, KS
Posts: 382
Default RV-7 Andrew Z #73658

Hello, everyone.

Years ago, I started my build, and started documenting it at my builder's log, but love the idea of also documenting it here, for posteriety.

I'll try not to flood the forums with posts.
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Andrew Z.
Engineering Flight Test Pilot/Engineer, CFI-A, CFII
RV-7 in work (See my build log.)
Empennage...Done (except rebuilding the rudder.)
Wings...Halfway complete.
2018 Dues Paid
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  #2  
Old 08-23-2017, 09:48 PM
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Bullseye Bullseye is offline
 
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Default 8/21/2009

Welcome to the site, and welcome to the first post. Over the last few weeks I've been starting to contemplate the dream of owning my own aircraft, and I think I am going to pull the trigger on it.

Anyway, I headed over to the Van's Aircraft website and ordered the preview plans for the RV-7/7A.

At $55 (plus shipping), I didn't think this was money poorly spent to get the chance to read through the builder's manual, see a set of 11x17 plans, and start planning out equipment, systems, modifications, etc. Ordering the Preview Plans actually seems like less of a commitment than getting this site set up. I'm not sure what that means about my commitment.

Over the next few months, I'll be getting ready to order the empennage. Now I'm just waiting for the delivery guy...
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Andrew Z.
Engineering Flight Test Pilot/Engineer, CFI-A, CFII
RV-7 in work (See my build log.)
Empennage...Done (except rebuilding the rudder.)
Wings...Halfway complete.
2018 Dues Paid
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  #3  
Old 08-23-2017, 09:50 PM
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Bullseye Bullseye is offline
 
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Location: Wichita, KS
Posts: 382
Default 8/27/2009

Last night, the preview plans arrived. They include some welcome pages, an RVator sample, a Van’s accessories catalog, the construction manual, and all the plans from the project printed on 11″ x 17″ paper. They come in a big grey binder.

I sat the binder on the table and stood back and looked at it thinking, “I bet this binder really doesn’t convey the enormity of what I am getting myself into.” After staring for a few minutes, I decided to dive in. I made it through the introductory pages and contruction techniques sections before heading to bed. I’ll start reading the actual construction manual this week and next.

Here’s the plan: the first time through, I just want an overview. The second time through, I am planning on outlining what tools, supplies, etc. I need and when I need them by adding a sheet behind appropriate pages and keeping a list. We’ll see how that goes. I’m trying not to buy tools needed only for the finish kit before building the empennage. More later…
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Andrew Z.
Engineering Flight Test Pilot/Engineer, CFI-A, CFII
RV-7 in work (See my build log.)
Empennage...Done (except rebuilding the rudder.)
Wings...Halfway complete.
2018 Dues Paid
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  #4  
Old 08-23-2017, 09:51 PM
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Bullseye Bullseye is offline
 
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Against some advice, I opted for the eBay purchase of a Rivet gun:



Chicago Pneumatic 4x Rivet Gun Riveter
Model: CP4444 RUTAB
Comes with AN470 3/32", 1/8", 5/32" & 3/16" Rivet Sets
3 Flush Sets
2 Rivet Set Retaining Springs
1 Conavair Aircraft Bucking Bar

August 31 update:

The rivet gun showed up, was in great shape, and after a few tries against the bucking bar, I believe I have determined that it works. How long it will last, however, is another story. I am happy for now that I have a gun that works and that it didn't break the bank.
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Andrew Z.
Engineering Flight Test Pilot/Engineer, CFI-A, CFII
RV-7 in work (See my build log.)
Empennage...Done (except rebuilding the rudder.)
Wings...Halfway complete.
2018 Dues Paid
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  #5  
Old 08-24-2017, 02:15 PM
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bret bret is offline
 
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Location: Gardnerville Nv.
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Pull out one of the fuse drawings and look for a busy one, now start at the top and try and decipher every detail, every note, every rivet call out ect, by the time you get here there will be little hand holding and a lot of attention needs to go into these drawings, I would take one or two to work and study them when I had a chance....for hours....and of course all the info on here. Have fun!
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  #6  
Old 02-09-2018, 10:38 PM
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Post Title: EAA Workbench Completed
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Sun, 30 Aug 2009 17:13:31 +0000
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After some planning about space and layout in the garage, I decided to dive into the construction of a workbench. I've heard (and seen on some builder's sites) some of the EAA 1000 Workbenches, and I thought that would be a good first workbench. I'll use that one for awhile before building a second one, hopefully with some improvements.

UPDATE: I built a second one. See the other post for pictures of the second one.
EAA Chapter 1000 Standard workbench plans.
EAA Chapter 1000 Standard workbench instructions.

Here's a couple before pictures of my garage.
I love the lighting. There was a single incandescent bulb in the garage before. Also, I lined the garage doors with some double sided bubble foil I bought off eBay. I would say adding that decreased the temperature in my garage in the middle of the summer by 10 degrees. Good investment.

I also installed pegboard along the entire NW wall and on the half of the SE wall that wasn't finished. The tools are just thrown up on the wall for now; I promise to get organized before I purchase the empennage kit.

Some shelves I built early after moving in for more space. Look closely, and you can see my cornhole boards supporting some old laptop speakers. When hooked up to my iPhone, they are loud enough to hear through my hearing protection (which I use religiously with power tools).

Smaller shelves on the SE wall (and more pegboard). Good for tools.
__________________
Andrew Z.
Engineering Flight Test Pilot/Engineer, CFI-A, CFII
RV-7 in work (See my build log.)
Empennage...Done (except rebuilding the rudder.)
Wings...Halfway complete.
2018 Dues Paid
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  #7  
Old 02-09-2018, 10:39 PM
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Bullseye Bullseye is offline
 
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Here's the top of the workbench (you build from the top down). Instead of 5 feet (60"), I decided to do 6 feet (72"). I added another rib (airplane talk!) which makes the spacing 14.1" on center (Instead of the ~15" mentioned in the EAA plans).

The legs and leg doublers got cut and mocked up. And no, I am not working barefoot.

It's actually starting to look like a workbench.

After adding the other leg doublers, I fastened some 200 lb locking casters on the bottom. I stuck to the plans on height (33") because I knew the casters would add a few inches. My sawhorses were built to 36", and I am happy with that height. The finished work bench is pretty close to 36".

Flipped and looking like a workbench.

Then I cut some Medium Density Fiberboard (MDF) for the benchtop, overhanging each side by about 3". I've been told to do this so I can clamp airplane parts to the bench more easily. Figuring I'd be replacing the top a few times during the project, I secured it down with some countersunk screws. Hopefully I'll get the vise bolted down in the next few days.


Is this where I say, "Ta Daaaa..."?
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Andrew Z.
Engineering Flight Test Pilot/Engineer, CFI-A, CFII
RV-7 in work (See my build log.)
Empennage...Done (except rebuilding the rudder.)
Wings...Halfway complete.
2018 Dues Paid
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  #8  
Old 02-09-2018, 10:43 PM
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Post Title: More tools arrive
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Sat, 05 Sep 2009 12:57:04 +0000

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A few days ago I ordered some more tools from the Yard. Acquisitions include:

A Hand Squeezer
11 Piece Squeezer set
Edge deburring tool
Air gun (not RV related, but for the shop anyway).

Today, I think I'm going to build a small storage rack (2x4 with some holes drilled into it) for my rivet and squeezer sets. I built one the other night that I wasn't happy with, so I'm going to try again. Here are a few pictures from the effort. Basically I laid out all the things that I thought could roll off the workbend when I needed them (plus the bucking bar, that won't roll). Then I drilled the 2x4 to correct size, making sure to be sloppy with the drill (I want there to be some play for a loose fit).
Here they are laid out.


After sanding, priming, and putting the sets into my holder, here is the final product. The space to the right is reserved for drill bits and dimple die sets. (I originally stole the idea from someone talking about drill bits. They said they always grabbed the wrong one, lost them, etc.) This is my version of the solution.


I think I'll put 3 or 4 of the most commonly used bits to the right along with some dimple die sets. I like it so far. We'll see if I just leave it on the workbench or actually mount it somewhere. Maybe somehwere attached to the workbench, or maybe on the wall by the compressor. I'll think about it.
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Andrew Z.
Engineering Flight Test Pilot/Engineer, CFI-A, CFII
RV-7 in work (See my build log.)
Empennage...Done (except rebuilding the rudder.)
Wings...Halfway complete.
2018 Dues Paid
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  #9  
Old 02-09-2018, 10:49 PM
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Bullseye Bullseye is offline
 
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Post Title: Ordered some more tools. Again.
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Tue, 15 Sep 2009 20:40:03 +0000
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Ordered some more tools today. I'll update the post when they come in. I've been ordering from The Yard, given the price advantage. Until I run into bad quality, I'll probably just continue along that route. I'm sure some of you may have some comments about that.

Here's the list. So far, project costs is $596 dollars. I have a spreadsheet I keep with estimated cost for each tool, then my actual costs, including shipping (free if order is over $100 with the yard). Then I calculate how much I save for each tool or item. I'm estimating I've saved about $678 by shopping around vigorously.

K Series Spring Cleco 3/32" (0-1/4")
K Series Spring Cleco 1/8" (0-1/4")
Cleco Pliers with Grip
#30 High-Speed Jobber Bit - 135 degee Split Point
#40 High-Speed Jobber Bit - 135 degee Split Point
Auto Center Punch Large
Safety Glasses Clear
Plastic Spring Clamp Small
Plastic Spring Clamp Medium
12" Drill Bit High Speed #30 AED
12" Drill Bit High Speed #40 AED
Dimple Die Set 3/32" Male/Female
Dimple Die Set 1/8" Male/Female

9/18/09 Update: The above ordered tools arrived, and I am again happy with their quality. I added some more spaces to the right of my rivet/squeezer/dimple set tool holder of sorts. Here are a few pics of the tools and their new home.
A closeup of the first of many clecos.

Clecos and Pliers. I sprung for the pliers with handles. High class, huh?

DRILL BITS!

Everything in the order.

And a punch.


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__________________
Andrew Z.
Engineering Flight Test Pilot/Engineer, CFI-A, CFII
RV-7 in work (See my build log.)
Empennage...Done (except rebuilding the rudder.)
Wings...Halfway complete.
2018 Dues Paid

Last edited by Bullseye : 02-15-2018 at 11:18 AM.
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  #10  
Old 02-09-2018, 10:50 PM
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Post Title: Purchased Practice Kit from GBI
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Sun, 27 Sep 2009 22:25:25 +0000

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I am a lucky guy. I live about an hour away from George and Becki Orndorff of GeoBeck, Inc. See their website at fly-gbi.com. Last night, after a wonderful day of flying a Cessna 310H to Gilliam McConnell and having lunch at the Pik-N-Pig, I drove down to see George and Becki and purchase a practice kit. After graciously forgiving me for bothering them on a Sunday evening, George showed me their RV-7A (N289GB). It was immaculate. I asked George about a few things, the answers to most of which were expected. Example: Why shouldn't I build? ("You should!") Do you love it? ("Absolutely!") Everyone I ask has nothing but wonderful things to say about their RV. Sounds like I need to go ahead start!

Two of his answers were more interesting. I asked him about tip-up versus slider, noting that everyone seems to like what they have. His simple response: "I've built both, and the slider is better. I won't build another tip-up." I was sold, but I pushed to find out why. Basically, he explained that the slider was more sturdy, cooler (both hero-pilot style and temperature style) and easier to build. Easier to build? That's contrary to what I've heard, but George is obviously trustworthy in the RV expertise area, so I'll take is word for it.

The other answer was to "What modifications should I do to the RV-7?"

He told me to put the RV-8 rudder on the RV-7 (instead of the RV-7/9, larger "uglier" rudder). I haven't seen pictures side-by-side (to determine if I agree with the ugly part), but George said the larger rudder on the 7/9 is for spin recovery. I'll need to think about this some more. I am not too concerned about spin recovery (he said it only improved the recovery from 1.5 turns to 1 turn), so I think the choice will come down to aesthetics, and the fact that the trailing edge of the 8 rudder is bent, while the 7/9 rudder is double-flush riveted.

Anyway, I got home with the kit, and had to join the girlfriend for dinner, so all I did was unpack the kit, and lay it out nicely so I can take pictures tomorrow before I get started.

Most importantly, the kit is a Van's kit (some other builders were wondering what the difference was), but also comes with GBI's sheet metal tools DVD. $55, which, with some subtraction skills, puts the DVD at $20. I watched the DVD last night, it runs about 60 minutes, and was really helpful with introducing me to some of the tools and techniques I am going to become intimately familiar with over the course of the project. He also walks through the actual construction of the practice kit. It's worth the $20. I also bought the pre-punched empennage kit videos. Those should come in handy soon enough.

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Andrew Z.
Engineering Flight Test Pilot/Engineer, CFI-A, CFII
RV-7 in work (See my build log.)
Empennage...Done (except rebuilding the rudder.)
Wings...Halfway complete.
2018 Dues Paid
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