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  #21  
Old 04-15-2018, 11:10 PM
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Tdeman Tdeman is offline
 
Join Date: May 2017
Location: Salem, OR
Posts: 29
Default Top Skin and Canopy Decks

In order to finalize the position of the ribs and sub panel, I made a bunch of small angles that spanned the notches/had the cutouts required for the sub panel and stiffener.


With the assembly somewhat rigid, I felt comfortable working on the top skin...




The outside curves of the sub panel, and the longeron to top skin holes were the only ones that needed to be back drilled.


With the skin ready for trimming/deburring/dimpling, I set it aside to work on initial fitting of the canopy decks.


When it was finally time to clean up this evening, the canopy decks were both ready for final deburring/notch cleaning, and countersinking.

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  #22  
Old 06-27-2018, 11:19 PM
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Tdeman Tdeman is offline
 
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Default Drilling, drilling, drilling

RV-6 Update:

Iíve been taking advantage of the (rare) Oregon sunshine the past several weeks surfing and biking, but managing to get some RV-6 construction done in the evenings after work.

Did a bit with the baggage floor and forward seat pans...




Cut out some bulkhead stiffeners, and got the top J stringers temporarily riveted in place...



Began to fit rear aft top skin...







I ran out of edge distance with a few rivets near the forward end, so decided to remake the aft skin from an extra sheet of 2024.
Initially slightly bigger than the first one, the holes transferred in just a couple minutes.



The front aft-skin was much quicker and had better drill access.

Of course then I had to throw the forward top skin on, the seats in, and the baggage floor in to make it look like Iíd made some real progress.









Plenty of drilling/hole layout to go, but such is the life of pre-pre-punched RV construction. Iím looking forward to fabricating less parts, and riveting more assemblies in the future!
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  #23  
Old 06-28-2018, 01:40 AM
RV7ForMe RV7ForMe is offline
 
Join Date: Jul 2015
Location: Europe
Posts: 405
Default

Quote:
Originally Posted by Tdeman View Post
RV-6 Update:
Plenty of drilling/hole layout to go, but such is the life of pre-pre-punched RV construction. Iím looking forward to fabricating less parts, and riveting more assemblies in the future!
Being a -7 builder I cannot even begin to imagine the amount of work it must be to get this thing drilled straight. That said I enjoy seeing your Fuse come together. Looking like an airplane already..
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  #24  
Old 06-28-2018, 11:53 AM
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jcarne jcarne is offline
 
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Location: Worland, Wyoming
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Default

Quote:
Originally Posted by RV7ForMe View Post
Being a -7 builder I cannot even begin to imagine the amount of work it must be to get this thing drilled straight. That said I enjoy seeing your Fuse come together. Looking like an airplane already..
I do however envy never having to worry about holes not lining up.

By the way your work looks really good!
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  #25  
Old 06-29-2018, 02:07 PM
greghughespdx greghughespdx is offline
 
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Location: Aurora, OR
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Lookin good, t-man. You get yourself wedged into in those seat frames and make airplane sounds yet?
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Building RV-8A since Sept 2014 (N88VX reserved)
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  #26  
Old 07-25-2018, 12:57 PM
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kentlik kentlik is offline
 
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Hey! How is the project coming along? Are you about to hang the engine? Just kidding, I get that a lot...

Looking very good.
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  #27  
Old 09-16-2018, 03:29 PM
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Tdeman Tdeman is offline
 
Join Date: May 2017
Location: Salem, OR
Posts: 29
Default Back to Building

It's getting too cold to surf, friends are heading back to university, and the mountain bike trails are still beat out from the summer of riding. That means it's time to get back on the build after several months of enjoying life outside the hangar.

First few items to take care of were small things I had been putting off a while, and a great chance to try out some of the new machine tools in the hangar.

My old (1994, non powder-coated) flap handle had some pretty deep corrosion pits on one of the arms. So I ground down the effected areas, and welded on a small patch of tube.

IMG_9197

Primed it, and then machined the slot for the manual flap-positioning mechanism, and also shortened the handle a few inches.

IMG_9227

I had already fit the flap bearing blocks on the outboard ends, but the middle bearing block sits part on the baggage floor, and part on the seat pan/tunnel. Rather than shim it with washers and have nutplates/fasteners out of plane with the surfaces, I machined a small set of wedges which got riveted to the tunnel cover, and to the seat rib, allowing the nutplates, bearing block, and bolt to all sit flat/vertical.

IMG_9230

I don't have a great vise for the mill, so starting with angle makes for easy work holding on small parts.

IMG_9237

(Ignore the too short, unset rivet in the above photo. It was used for aligning purposes only)

This should keep the fasteners happy.

IMG_9239

I wasn't happy with the previously made angle for the attach of the horizontal stab. Edge distance under the longerons was getting small, and these holes had to be further upsized for the AN-3 bolts.

The mill was already dirty, so I figured I might as well knock out a new one which could maintain every (thousandth) of an inch possible under there.

IMG_9215

IMG_9214


The original aft baggage side-panels did not fit real well (flanges would not sit flush with all mating surfaces), so I bent a new set on the brake which fit much better.

IMG_8904

Next is finalizing the custom seat pans (accommodating the 1" lowered seat ribs), and then some interior items might be going on permanently!

It's been a lot of making parts thus far, but one of these days the rivet gun is going to come out for more than a few whacks

IMG_9240

Canopy frame and baggage bulkhead coming soon.
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  #28  
Old 09-16-2018, 03:37 PM
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Tdeman Tdeman is offline
 
Join Date: May 2017
Location: Salem, OR
Posts: 29
Default

Quote:
Originally Posted by RV7ForMe View Post
Being a -7 builder I cannot even begin to imagine the amount of work it must be to get this thing drilled straight. That said I enjoy seeing your Fuse come together. Looking like an airplane already..
Thanks! A lot of it just comes down to work holding and throwing on more clamps than you think you need.

Quote:
Originally Posted by jcarne View Post
I do however envy never having to worry about holes not lining up.

By the way your work looks really good!
Thanks Jereme, seeing your surge of progress was more than motivational to get out there again.

Quote:
Originally Posted by greghughespdx View Post
Lookin good, t-man. You get yourself wedged into in those seat frames and make airplane sounds yet?
Sure have! The more parts that get put in, the louder the noises seem to get.

Quote:
Originally Posted by kentlik View Post
Hey! How is the project coming along? Are you about to hang the engine? Just kidding, I get that a lot...

Looking very good.
Kent, your progress is also looking good, and an appreciated reminder to keep moving forward
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  #29  
Old 12-15-2018, 11:54 PM
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Tdeman Tdeman is offline
 
Join Date: May 2017
Location: Salem, OR
Posts: 29
Default Cold Progress

Itís been cold out in the hangar, but Iíve tried to keep the progress moving. I built a visqueen box to try and keep some heat in, and some moisture out, hence the change of backdrop! One benefit is it reflects much more light from the sides.

Finally tackled the seat pans. Things not quite being perfectly straight 90 degrees to each other in this area made it difficult to bend single sheets to fit everything for the lowered seat ribsÖ So a 3-piece seat pan was built because it was easy to make it register well on all surfaces.

IMG_9318

IMG_9351

Got the holes cut out in the forward seat pan as well for the control sticks. Also took a deep breath and did my spar carry through cutouts in the F-604. They came out real nice, with no gashes to the carry through.

IMG_9374

Of course with interior pieces finally coming together I had to throw them in to see how things were looking. Some fit and finish work is still required for a few interior panels, but overall most of the interior aluminum parts have been bent/shaped/drilled/fit.

IMG_9359

IMG_9512

Finally finish trimmed and zipped on the rear deck and aft tailcone skin.

IMG_9613

IMG_9638

And Lately Iíve moved on to some canopy fitting. Got the roll bar all fit, and slider tracks initially positioned. Traced canopy frame onto forward tailcone skin and made an initial skin trim just to allow it to sit in place.

Canopy frame tweaking will be next!

IMG_9679

IMG_9679
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