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  #61  
Old 08-17-2017, 09:11 PM
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CubedRoot CubedRoot is offline
 
Join Date: Sep 2013
Location: Ooltewah, TN.
Posts: 548
Default February 27th, 2017. Hours Worked: 2

After having a lot of things going on today, I decided to get down to the shop and build a little on the airplane to help clear my mind. Our little 9 month old, Acacia, had to be put in a brace for her hip dysplasia for a few weeks, so that broke mine and Tammys hearts 🙁 Getting down in the shop and working on the plane and working with my hands is a good stress reliever for me so I figured Iíd go do some build-therapy for a few hours tonight.

Since I am waiting on a good full day to prime the rest of the elevator parts, the only thing I have left to work on right now is the trim tab. I had previously assembled it, so I started this session by deburring all the trim tab parts, and dressing the edges of all the parts. Then I dimpled the skin using my squeezer, because the tight spaces wouldnít allow it in my DRDT-2.



The E-607PP trim tab spar needs to be machine countersunk only on the top side so it can receive the dimpled skin, but we canít dimple it because we donít want a bulge on the bottom, where the hinge will attach. I fired up my micro-stop countersink and knocked this out pretty easily, and then followed it up by dimpling the bottom of the spar with my dimpler per the plans.



After all the parts were deburred, dimpled, dressed and countersunk, I went ahead and assembled everything to start riveting. I riveted on the bottom side of the skin to the spar using my squeezer, but this was not a fast process. I had to use a few blocks of scrap wood to hold the skin open in order to get my squeezer in there. It was still a tight fit in most of the spots, so I had to pay extra attention to what I was doing.



I left the E-717 and E718 trim tab horns for the very last so I didít risk bending or damaging them during this process. I also used a cleco to help hold the hole for the clevis pin in alignment on the trim tab horns just to be safe. With a little bit of patience and fiddling, the bottom of the skin was riveted onto the spar.



I am going to hold off on attaching the top part of the skin to the spar, because we have to do some measuring of the trim tab against the elevator in order to align both halves of the hinge just right, so for now, I just clecoed it on and then attached the forward half of the hinge to keep the hinge pin safe and free from getting bent on the shelf. Thatís about all I got done tonight. A total of right at 2 hours of work and I called it a night. Hereís the photos from tonights session: https://goo.gl/photos/rVtTaemn4fUUSQfX7

Hours Worked: 2
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Lynn Dixon
RV-7 Slider -
Tail kit Completed - March 2017
Wing Kit Started - June 2017
My Build Log: http://www.theskunkwerx.com

VAF Donation paid for 2017
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  #62  
Old 08-17-2017, 09:12 PM
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CubedRoot CubedRoot is offline
 
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Location: Ooltewah, TN.
Posts: 548
Default February 28th, 2017. Hours Worked: 3.25

Well, tonight was priming night, and its the last priming session for the entire empennage! I am kind of glad to be honest, spraying AKZO is an ordeal with all the PPE and prep work that has to be done. However, it leaves an absolutely awesome primed surface, that is incredibly durable so I guess its worth the trouble. I only had a few remaining parts from the left elevator that needed priming, and I have decided I am not priming the trim tab. Its a super small piece, and the assembly work left the trim tab fairly closed, so I wouldnít get much coverage in it anyways. Even if the trim tab starts corroding (it wonít its alclad), the entire thing will cost about $50 in parts to replace, and maybe 8 hours of work. The trim tab finished out so well, that I didnít want to chance ruining it by trying to prime it.

Hereís my obligatory priming selfie!!!



Like all priming sessions, I started out by scuffing up the parts with maroon scotchbrite pads. These things work great at scuffing the alclad surface, but not removing it. I essentially am just removing any of the alclad surface corrosion and giving the primer a good surface to ďbiteĒ onto. Once I had all my parts scuffed up, I did a quick wipe with a microfiber cloth to remove the dust that scuffing leaves behind. I have found this small step makes it WAY easier to clean with acetone. Once I had the dust off the parts, I cleaned each one with acetone 3 times each and using a clean side of a paper towel every time. I like to clean the parts until the white paper towel pulls away clean from the part.

Then, I mixed up the AKZO and let it kick-off for the 30 minutes it needs, stirring it occasionally. I made 4 ounces of AKZO for this small batch and then poured it into the PPS cups for my HVLP sprayer. While the AKZO was kicking-off, I suited up into my tyvek suit, donned my full face mask and sealed off the spray booth and ventilated it outside. Like usual, AKZO sprays super easy, and covers wonderfully with an HVLP. Usually once quick pass is enough to cover the part completely, with only needing a few small touch upís in the shadowy areas.

Once I had all the parts sprayed on both sides, I cleaned out my sprayer and Iíll leave the parts to cure for a few days. AKZO dries really fast, and is workable in a few hours, but I like to let it completely cure before working with it. Its very scratch resistant if you do. Not many photos tonight, because, well its priming. Its pretty much the same as the other priming sessions 🙂 Hereís the ones I did take though: https://goo.gl/photos/Bm6Ck64TDSQRLVNj7

Hours Worked: 3.25
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Lynn Dixon
RV-7 Slider -
Tail kit Completed - March 2017
Wing Kit Started - June 2017
My Build Log: http://www.theskunkwerx.com

VAF Donation paid for 2017

Last edited by CubedRoot : 08-19-2017 at 12:39 PM.
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  #63  
Old 08-19-2017, 12:43 PM
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CubedRoot CubedRoot is offline
 
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Location: Ooltewah, TN.
Posts: 548
Default March 2nd, 2017. Hours Worked: 3

The primer has dried and cured on my left elevator parts, so theres only one thing left to doÖ Start assembly and riveting! I started out the session by bending the tabs on the elevator skin. On this left skin, there are two tiny little tabs that must be folded over, just like the trim tab, in order to close the edge where the trim tab sits. These also support the outboard edge of the skin, much like a rib would. This is a very delicate operation, and one that can go wrong quickly. When I bent the trim tab, I had a second one for a spare so I didnít worry. With this skin, I only have the one, and I have a ton of work in it already! I used the same bending blocks as I did for my trim tab, since the angles are pretty much identical. I inserted the block and clamped it down to the bench. I used a straight edge held against the block of wood to make sure I had it right on my bend line.





We bend the bottom tab first, and then fold the top tab over the top this way we form a lip that allows water to run over the skin, and not get trapped between the tabs, or worse, get inside the skin! Notice my note to myself (1 st!) so I donít bend the wrong tab first. I used a large block of wood and a small hammer with light taps to bend the bottom tab into position. Once I had the bottom tab where I liked it, I did the same with the top tab, and the end results were decent. While they are not perfect, and have a few tiny dents from the bending, I am happy with them as they are. The dents wont be visible since they are on the inside of the edge and will have the trim tab butted up against them.



Next up, I dimpled all the parts and skin. I like to dimple after priming because it makes scuffing in preparation for priming so much easier. I dimpled the skin, spar, end ribs and all associated parts for the left elevator. I used a combination of my squeezer and the DRDT-2. I had to use my squeezer on the skin this time, due to how tight the trailing edge is. Once I had all my parts dimpled, I continued on with the rest of the plans. In the section titled ďRiveting the Left ElevatorĒ, Vanís has us start out by riveting E-704 End Rib and E-703 counterbalance rib together.



After that, we move on to riveting the E-610PP and E611PP reinforcement plates to the E-702 spar, along with the E-00001A and E-00001B doublers and the rivnuts. We have to be very careful here, as there are three different rivet lengths that attach all these together. I used the squeezer to set all these rivets.





I was running a bit out of gas, so I decided to finish up the session by knocking one more simple little part: The trim tab servo plate and brackets. This is a simple part and only requires about 6 rivets. I used the squeezer to set these flush rivets, and then test fitted the servo to make sure it was still all in alignment. It came out great.







Thats all for tonight. I still have a little bit more riveting to complete, so I will leave that for the next session. I have also spoken with my local EAA Tech Counselor, and heís going to come by this Saturday afternoon to give my project a look. I still have the horizontal stabilizer, vertical stabilizer and elevators to close up, so I will leave them until he can inspect them before closing them up. Hereís all the photos for tonight: https://goo.gl/photos/MEyHbRc28WovGerUA

Hours Worked: 3
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Lynn Dixon
RV-7 Slider -
Tail kit Completed - March 2017
Wing Kit Started - June 2017
My Build Log: http://www.theskunkwerx.com

VAF Donation paid for 2017
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  #64  
Old 08-19-2017, 12:48 PM
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CubedRoot CubedRoot is offline
 
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Location: Ooltewah, TN.
Posts: 548
Default March 4th, 2017. Hours Worked: 1.75

Since I have had my horizontal stabilizer inspected and approved, I am ready to close it up and finish it! I started tonights session by re-clecoing the front spar onto the horizontal stabilizer. I had removed it so the inspector could get a good look inside and check my work. Once I had it all clecoed on, I double checked the orientation to make sure it was all correct.



Once it was all clecoed into place, the rest was pretty easy! I dropped in AN4263-3.5 rivets and squeezed them with my pneumatic squeezer. I skipped every other hole with clecos, so once I had the unclecod holes rivets squeezed, I went back and removed the clecos and riveted them. Squeezing makes a very nice rivet and everything came out looking very nice.





Once the rivets were set along the spar and skin, there were a few that we had to get to on the ends that attached the HS-706 tip rib to the HS-603PP rear spar. Those are using AN470 rivets, but I was still able to get them with the squeezer.



Then, there are 4 blind rivets that we have to set using a pop-rivet tool. These are what attach the HS-603PP rear spar to the HS-708 main rib, and we have to use BSPQ-5-4 blind rivets in these holes. These are some pretty beefy blind rivets, and it took a good bit of force on the pop rivet tool to get them set, but they came out looking great.



Finally, there are a few more AN470 universal head rivets that attach the HS-00005 inboard aft rib to the HS-603PP rear spar, but I was able to use a squeezer to set these. They are fairly long -7 rivets due to all the metal they tie together.





I did also cover my bolts with some torque seal, and made a **** of a mess with it! As you can see in the photos, this stuff is like Pro-Seal, and gets everywhere! I tried to clean it up the best I could and made sure the bolts were covered to make inspections easier. That was it for closing up the horizontal stabilizer! One of the suggestions that the Tech Counselor made was to make sure I included plenty of photos of me doing the work, which is a bit difficult given that I am building this plane all alone. I decided to use my old Go Pro and do some timelapse videos. I will include them in future posts. Here is the obligatory selfie of me holding the finished stabilizer!



And here is the time lapse video of the construction. I set the Go Pro to do a photo every 10 seconds, I may do it at 5 seconds on the next video. Let me know what you think.

https://youtu.be/lXyJUsTrnQg

Link to Google Photos: https://goo.gl/photos/RABUeY3Z4gXmMA9U9

Hours Worked: 1.75
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Lynn Dixon
RV-7 Slider -
Tail kit Completed - March 2017
Wing Kit Started - June 2017
My Build Log: http://www.theskunkwerx.com

VAF Donation paid for 2017
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  #65  
Old 08-22-2017, 09:52 PM
gfb gfb is offline
 
Join Date: Jul 2014
Location: Madison, WI
Posts: 485
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Nice work! Really coming along!
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  #66  
Old 03-27-2018, 11:55 PM
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CubedRoot CubedRoot is offline
 
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Location: Ooltewah, TN.
Posts: 548
Default March 4th, 2017. Hours Worked: 1

After completing the horizontal stabilizer in a previous work session, I decided to continue on and finish the vertical stabilizer. *The Tech Counselor came out this morning and approved all my work so far, and that means its safe to close these guys up and mark them as done! *I started out by clecoing the rear spar back on to the vertical stabilizer skin, we had removed it this morning so the inspector could take a good look at the riveting done inside.



Once the VS-803PP rear spar was clecod on, I inserted an AN426AD3-3.5 rivet into every other hole and used the squeezer to set the rivets. Once they were all done on both sides, I removed the clecos and then riveted those holes. Since I was able to use my squeezer, these rivets came out perfect:



Next up was to attach the VS-707 rib to the VS-803PP rear spar assembly using LP4-3 blind rivets. *These were easily done using the pop rivet tool, making sure to keep them flush with the parts when setting.



Finally, the last step was to rivet on the VS-704 end rib to the VS-803PP rear spar assembly using AN470AD4-6 rivets and then attaching the VS-706 tip rib to the rear spar using AN470AD4-4 rivets. *I used the squeezer on these guys, and they set really nicely. Its still very nice to see just how rigid everything ends up being once it all riveted together. These skins are nice and tight and have zero oil canning.





Here is a nice time lapse video I took of this session:

https://youtu.be/5-IIUhKBHhM

Of course, the obligatory happy selfie of the finished vertical stabilizer:



Google photos Link:*https://goo.gl/photos/SX4DAd6o8eWHGtPu7
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Lynn Dixon
RV-7 Slider -
Tail kit Completed - March 2017
Wing Kit Started - June 2017
My Build Log: http://www.theskunkwerx.com

VAF Donation paid for 2017
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  #67  
Old 04-12-2018, 09:26 PM
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CubedRoot CubedRoot is offline
 
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Default March 5th, 2017. Hours Worked: 3

link: http://theskunkwerx.com/rv7/riveting...elevator-skin/

# Riveting the Left Elevator Skin

Tonight I worked to rivet on the skin of the Left Elevator and the last few remaining parts of the skeleton for it as well. In the last work session, I completed the spar and a few other parts, but tuckered out before I got to the skin. I started out by riveting the E-703 tip rib assembly to the E-702 spar, making sure to get the hard to reach rivets first. The last time I did this on the right elevator, I left two rivets that were hard to reach with a squeezer in a bad position, and I spent a couple hours working on it to get them riveted. I learned to get those two first this time :-)



Once I had the tip rib squared away, I moved to the other end and riveted on the E-705 end rib to the E-702 spar, making sure to face the flush rivets in the proper direction so as to not interfere with the WD-605-1-L elevator horn that I riveted next. These all were pretty straight forward, and I used my squeezer to get a perfectly set rivet on them.



Now its time to move on to the skins. First, I attached the E-713 counterbalance skin to the E-701 elevator skin with clecos, and noted which two rivet holes I need to set first, before inserting the skeleton. I opted to set these rivets now, and use AN426 flush rivets instead of using pop rivets after the skeleton is inserted into the skin. We just have to be cautious to make sure we use the correct holes :-)

![[/url]

Before inserting the skeleton, I popped in some plastic snap bushings into the holes in the spar for the trim servo jack shaft and wiring. Its easier to do now than when the skin is closed up.

![[/url]

Now, its time to mate the skin with the skeleton, and cleco it all together for one last check before final riveting. I gently inserted the skeleton into the skin, and lined everything up and clecoed every hole. Once I had it all clecoed I used a straight edge against the skin to check its straightness, both on the stiffeners and between the stiffeners. Then I removed every other cleco to make riveting easier.



I only riveted the bottom skin for now. I will leave the top skin free so I can put pro-seal on the stiffener ends before closing it up for good. I closed the bottom skin by inserting a rivet in every other hole and squeezing it. Then I removed the clecos, and clecoed the holes they were in. On the left elevator we have to use 4 blind rivets on the outboard end of the E-606PP spar, as there is no way to get to it otherwise. I used MK319BS blind rivets in those last 4 holes, and made sure they were sitting as flush as possible. They were not 100% flush like the AN426 rivets, but they ended up flush enough to make me happy.



With that being done, all that remained was to mark and drill the holes on the tabs that I bent a few nights ago. Van's doesnt have these holes pre-punched, because its impossible to know where they'd end up after the bending, so we have to be creative. Van's does tell us to make sure the rivets from the trim tab do not interfere with the elevator skins, so I put the trim tab in its location, and marked where the pre-punched holes for it were on both the trim tab itself, as well as the elevator skin, seen in the photo above. I then decided to place my elevator tab rivets between where the trim tab rivets go, so as to give me plenty of clearance. I then drilled the holes with a #40 bit, followed by a #30 bit to fit the CS4-4 blind rivets. The last bit of work for the night was to bolt on the E-714 counterweight. I picked our the screws, washers and nuts as called for by the plans, ran them through the counterweight assembly and then torqued them down to 30 inch/lbs of torque as specified in the manual. Then, I gobbed on some torque-seal to make annual inspections easier in the future.

![[/url]

That finished up the work for tonight. Here's a quick time lapse of the work to make the FAA happy that I actually completed the work, and a photo gallery of all the photos below that.

https://www.youtube.com/watch?v=R7bv-Cgp1p4

Google Photos Link: https://goo.gl/photos/B2SmEbJ6Q8Gg9iM29
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Lynn Dixon
RV-7 Slider -
Tail kit Completed - March 2017
Wing Kit Started - June 2017
My Build Log: http://www.theskunkwerx.com

VAF Donation paid for 2017
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  #68  
Old 04-12-2018, 09:31 PM
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CubedRoot CubedRoot is offline
 
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Default March 9th, 2017. Hours Worked: 2.5

link: http://theskunkwerx.com/rv7/closing-up-the-trim-tab/
created: 2017/03/09 21:00:49

# Closing up the Trim Tab

I am coming down to the finish line on this empennage kit. Tonight I finished up with the elevator trim tab, and it is ready to be permanently attached. I had gotten it nearly completed the last time I worked on it, but I needed to get the elevator riveted up so I'd have a finished surface to work with. I started out the night by getting the trim tab lined up with the elevator. The trailing edge is critical, and needs to be perfectly in trail with the elevator trailing edge. Luckily, I had an easy way to make sure of this. I had some left over 2x2 angle, so I laid one side of the angle under the elevator, and let the other side function as my straight edge. I made sure the angle was sitting flush up against the trailing edge, and then I positioned the trim tab so that its trailing edge also fit flush against the angle. This made sure that both trailing edges were perfectly in alignment.



Once I was happy that the trailing edge was flush, I double checked the edges on the inboard edges as well, to make sure they are aligned together. Then it was time to clamp it all down and get to match drilling. I used a cleco side clamp to hold it, while I drilled the first hole on the inboard edge. Then I cleco'd that hole and re-checked my alignment and drilled the outboard hole which held the E-721 trim tab hinge from loosing its alignment.

![[/url]

Then I removed the trim tab, but left the forward half of the trim tab hinge clecoed to the elevator. I used all of my cleco clamps to help hold the hinge flush against the E-616PP spar. This also helped hold the hinge steady while I gently match drilled the remaining holes, using the E-701 as a guide.



After I got the forward hinge drilled to the elevator, I removed everything, and then deburred all the holes, and cleaned up the edges of the hinge, rounding the corners. The plans also has us mark and trim off the excess hinge from the inboard side, which was easy to complete. I dressed these edges as well. Next up was to rivet the hinge to the trim tab itself. I had triple checked that everything was still in alignment with the tab on the elevator, and then I drilled the holes for the end tabs on the inboard side of the trim tab, using a #40, followed by a #30 for final size. I clecoed those holes and then removed the trim tab to rivet everything. I riveted the trim tab hinge using my squeezer making sure I did not catch the loops of the hinge in the squeezer. Riveting this hinge cause a slight bend in the loops, so I spent some time gently bending the loops back into alignment, using the hinge pin to make sure. With that being done, I drilled the outboard end tabs and then used CS4-4 blind rivets to finish up both sides of the end tabs. With that, the trim tab is done!



Google Photos Link: https://goo.gl/photos/pV1jmjChAmoVbwpH9
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RV-7 Slider -
Tail kit Completed - March 2017
Wing Kit Started - June 2017
My Build Log: http://www.theskunkwerx.com

VAF Donation paid for 2017
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  #69  
Old 04-12-2018, 09:36 PM
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CubedRoot CubedRoot is offline
 
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Posts: 548
Default March 11th, 2017. Hours Worked: 1.25

link: http://theskunkwerx.com/rv7/proseal-party/
created: 2017/03/11 15:00:34

# ProSeal Party!

Today was actually a pretty fun day. I decided to wait on prosealing the rudder and elevators until I could do it all at once, and save on the cost of mixing up two different tubes for two different sessions. I also took advantage of having some helpful friends to come by and lend a hand at this super messy task, with the promise of feeding them some of Tammy's awesome "Mississippi Mud Pot Roast" as payment for their help. One of the helpers has had experience with ProSeal before, so he gave us some tips on using this stuff. Best tip: Double glove.... We started out by un-cleocing the trailing edge of the rudder so we could get the trailing edge wedge out and clean it. I used acetone to wipe down the wedge as well a both sides of the skin to make sure we get good adhesion, although after using ProSeal, I think this stuff would stick to anything. Once we had the parts cleaned off, we mixed up the tube of Proseal. This was actually a neat setup, and the rods made it pretty easy to get it all mixed up and proportioned correctly. Then we gooped on a decent portion on the trailing edge wedge, and smeared it to a nice even consistency using the pieces of some clothespins.





Having plenty of hands made this job go much smother. One guy squirted on the Proseal from the caulking gun, while we smoothed it out using the ends of the clothespins and pieces of some paint mixing sticks. Once we had the wedge good and covered with this sticky mess, two guys held the ends of the wedge, while me and the other helper held the trailing edge of the skins open just enough so they could slide the wedge in place. We lined it up with the holes and then used a few clecos to hold it until we could set it aside and then cleco it down to the 2x2 angle aluminum which serves as our straight edge. Before clecoing it down to the straight edge, I did run my finger using some force along the the trailing edge to make sure all the excess Proseal was squeeezed out to prevent pillowing between the clecos. Then, once we had all the clecos inserted, we went back and placed some clothes pins in between the clecos to help clamp it down even further. I also gave each one of the clothes pins an extra "squeeze" every so often by pinching the down on the nose of them.

![[/url]
![[/url]

With the rudder ready to be set aside and cured, we moved on to the elevators. I wanted to put a decent glob/dab of ProSeal at the ends of the stiffeners near the trailing edges. This is supposed to help fight off any vibration and keep the stiffeners from cracking, so I figured its worth the little bit of time to go ahead and do this. We started out by unclecoing both elevators, and then using a combination of paint mixing sticks, the caulking gun and finese to get a good blob of Proseal on each stiffener junction. Again, having several sets of hands REALLY made this job much easier. We ended up using nearly the whole tube (medium sized tube from Vans) on the rudder and both elevators.




After we had both elevators prosealed, we clecoed them back together, and I will finish riveting them in a few days once the Proseal cures. Just some words of advice:

1. Proseal is incredibly sticky, and WILL get everywhere.
2. Double glove...it makes it easy to pull off your outer layer, and slip on a new set. Sweaty hands from the gloves are hard to get a fresh pair on, so double gloving avoids this problem
3. This stuff smells like sewer and new tires. Make sure you have good ventilation. Its not as bad as AKZO, but man, its a weird smell.
4. It has a pretty decent working time of about an hour or so. Maybe more if you are willing to risk it. It was a little cold in the basement, so we didn't want to chance it.

Google Photos Link: https://goo.gl/photos/4fRLG915Z8FAGnmZ6
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Lynn Dixon
RV-7 Slider -
Tail kit Completed - March 2017
Wing Kit Started - June 2017
My Build Log: http://www.theskunkwerx.com

VAF Donation paid for 2017
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  #70  
Old 04-13-2018, 08:39 AM
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kentlik kentlik is offline
 
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Wow, that is really looking good! Having helping hands makes it more fun I would imagine.
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