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  #1  
Old 08-11-2018, 08:26 PM
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Brantel Brantel is online now
 
Join Date: Mar 2006
Location: Newport, TN
Posts: 7,019
Default Status: Brantel RV10 build

So it looks like I am gonna make a go at building an RV10.

That means I have to get my shop and tools back into build mode!

One of the tools that I said I would never build another airplane without was the DRDT-2. It is one of the best luxury tools anyone can own for building an aluminum airplane that uses flush rivets!

When I was building my 7, it was a struggle to fund the project and stay out of debt so I built my own DRDT-2 frame and purchased the front end kit from Paul Merems (creator and manufacturer of the DRDT-2) http://experimentalaero.com/

When I finished my 7, I regretfully sold my DRDT-2 to a fellow builder. Last I heard he finished his plane and he sold it to a third builder. Who knows how many planes that thing will help build over the years? (Sorry Paul!)

Fast forward to now and since I have decided to build again, I need to obtain or build another machine. Recently I put a WTB on the classifieds and originally planned to purchase a finished unit. At the same time I started trying to find the steel required to build the frame if I decided to go that route.

No used finished units turned up quickly. New units are available with a stiff shipping charge due to the weight. Steel prices are outrageous. Etc. All of this drives up the cost of this awesome tool.

So luckily I was able to source some steel wholesale thru my work and I was able to secure a front end kit second hand. (Sorry Paul!)

Yesterday my uncle and I set out to build another DRDT-2 frame.

I had used an horizontal band saw at work to cut the parts to length. It is absolutely necessary for some of the ends of the tubing to be perfectly square and perpendicular. Therefore for those parts and faces, I used a vertical milling machine to true up the parts.

Then it was on to the welding table. We don’t have a MIG welder so we stick welded them with low hydrogen rods. We TIG welded the top front ram mount faceplate to the top tube.





It is absolutely critical that the frame be straight, square, perpendicular, and strong in all the right places. Anyone that welds will know that welding can pull your parts in all kinds of directions so it is necessary to clamp, clamp, clamp! Also you have to be mindful of the welds, heat, etc.

Clamps!



More clamps!



Even more clamps!



So once the welding was done, I wanted it to look good so I put some filler in the right places and sanded it all smooth.




And finally, degreased and painted the frame with Rustoleum Hammered Black.

Looks great!





The front end kit should be here soon and when it shows up I will mount it up to the frame and be ready for dimpling.

Some notes:

There is a ton of work that goes into building this frame correctly. If the top front end ram mount face is not perpendicularly to the bottom beam, the dimples will be negatively impacted and poor quality. Paying close attention to the build will eliminate the need to shim the ram and or lower die holder later to get it all to run true. The high cost of steel, welding gear and consumables, paint and labor makes it hard for me to imagine how Paul sells his completed units for the price he does! Do yourself a favor and just pay the man and buy his ready made unit!

On my original years ago I used 1/4” wall tube when the plans only call for 3/16” because that is what I had on hand. I decided to build this one out of 1/4” as well because I learned to love the extra beef in the original. I am sure the 3/16” would be fine however.
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  #2  
Old 08-11-2018, 10:08 PM
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9GT 9GT is offline
 
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I sold my original DRDT-2 when I sold my -10 thinking I was done. A year later I am back at it on a -9A and had to replace ALL my building tools I sold. I also decided to build my own DRDT-2 style dimpler. I sourced my steel pre cut to lengths needed from an on-line metal supply and the lever clamp off amazon. Machined my own adjustable die holder. Welded it up and painted it. Feeling very pleased with myself only spending $100 on materials. . I kid you not, a week later I am at a garage sale in a rural community and there on the garage floor is a DRDT-2 machine. The guy says $5 will buy it..He even knew what it was! I like the one I built a little better because I made the throat 2” deeper so I sell the garage sale find to a fellow builder here on the forum.
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RV-10: N959RV Completed 12/29/2013 SOLD 08/23/2016

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  #3  
Old 08-12-2018, 07:27 AM
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scard scard is online now
 
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Moral of the story....

Never sell a tool... unless it is to make space for a bigger better replacement .
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  #4  
Old 08-12-2018, 07:34 AM
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Brantel Brantel is online now
 
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Quote:
Originally Posted by scard View Post
Moral of the story....

Never sell a tool... unless it is to make space for a bigger better replacement .
Yes, what he said!
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Brantel (Brian Chesteen),
Check out my RV-10 builder's BLOG
RV-10, #41942, N?????, Working on Emp/Tail Cone
---------------------------------------------------------------------
RV-7/TU, #72823, N159SB
Lyc. O-360 carbed, HARTZELL BA CS Prop, Dual P-MAGs, Dual Garmin G3X Touch
Track N159SB (KK4LIF)
Like EAA Chapter 1494 on Facebook
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  #5  
Old 08-12-2018, 08:00 AM
mturnerb mturnerb is offline
 
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Location: Ponte Vedra, FL
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This thread is well-timed. I'm getting close enough to finishing my RV-14A that I'm thinking about what to do with/about tools. Bottom line - I'll find it very hard to part with them and can think of ways I might use them as an owner as opposed to a builder. Not to mention the risk of becoming a "repeat offender"...
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  #6  
Old 08-12-2018, 11:10 AM
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uk_figs uk_figs is offline
 
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Default Very true

Quote:
Originally Posted by scard View Post
Moral of the story....

Never sell a tool... unless it is to make space for a bigger better replacement .
Needed to repair some ribs on my Champ project yesterday, out comes the right angle air drill, the pneumatic squeezer, the dimple die set, the rib flange tool, the flange shrinker tool, the hand cutting tools, the nibbler, the left over rivets, the clecos.

2 hours later ribs repaired and look as good an new

Who would have thought to keep all these tools to work on a tube and fabric aircraft.
Figs
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  #7  
Old 08-13-2018, 06:39 AM
Maddawg99 Maddawg99 is offline
 
Join Date: Apr 2015
Location: Tiger, GA
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I built this one much like you did yours. I had some 7x3x.250 steel laying around and used it. It should have less flex, so all good. I also drilled and tapped the face while I had it on the mill. Then powder coated in gas can red


[IMG][/IMG]
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  #8  
Old 08-13-2018, 10:28 AM
EXflyer EXflyer is offline
 
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Default Tool

Would have been so nice along with a prebuilt spar years back when I did the wing on my -3.
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  #9  
Old 08-13-2018, 12:31 PM
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Brantel Brantel is online now
 
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It is official....

I am now a RV10 builder. The order for the emp/tail cone has been sent to Vans!

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Brantel (Brian Chesteen),
Check out my RV-10 builder's BLOG
RV-10, #41942, N?????, Working on Emp/Tail Cone
---------------------------------------------------------------------
RV-7/TU, #72823, N159SB
Lyc. O-360 carbed, HARTZELL BA CS Prop, Dual P-MAGs, Dual Garmin G3X Touch
Track N159SB (KK4LIF)
Like EAA Chapter 1494 on Facebook
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  #10  
Old 08-13-2018, 12:53 PM
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Captain_John Captain_John is offline
 
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Brian, good for you! I'm wondering whether or not I should build something again also. I would build a 10, but I don't have that many friends! LOL looking forward to seeing your progress!

CJ
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