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  #11  
Old 11-10-2016, 10:12 AM
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CubedRoot CubedRoot is offline
 
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Location: Ooltewah, TN.
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Default

Quote:
Originally Posted by RV7ForMe View Post
Welcome!
Looks like you right where I am at right now.
Awesome! I have found that I enjoy the assembly and drilling more than the metal prep so far. hah. At least during the assembly portion I feel like I am actually building something.

But its kind of nice to just chill out in the basement with some Blackberry Smoke playing drinking a few beers and deburring and prepping the parts.

Do you have a build log posted somewhere? I'd like to follow along!
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Lynn Dixon
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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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  #12  
Old 11-10-2016, 01:40 PM
RV7ForMe RV7ForMe is offline
 
Join Date: Jul 2015
Location: Europe
Posts: 274
Default Sort of...

Hey. Well I don't have a blog or anything. I have a thread here on VAF.

Build Project

I have had the kit for a while but I started a few weeks ago. I actually recieved my repaired compressor this afternoon. First test looked promising. I need to prep and prime and then assemble the first parts.

Same here. Prep work is a bit of a pain but I read it is really important bc of cracks that may form later. No idea I just do as best as I can. I made one mistake so far drilling but VANs said its just cosmetics "build on" is what they said actually
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  #13  
Old 11-10-2016, 10:28 PM
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CubedRoot CubedRoot is offline
 
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Default November 10th, 2016. 2 hours

Lots of part prep done tonight. I only have a couple hours I could spare, so I worked to wrap up all the prep work on the ribs, spars and skins.

Lots of deburring, edge breaking and smoothing, and filing on all of the left horizontal stabilizer. I also removed a few strips of blue plastic around the rivet holes on the skin, trying to leave as much as possible on the skin to help keep it protected. I used the soldering iron method to make the strips smooth and a ruler to help guide it. I also ground the tip of the iron down on my bench grinder so it's not sharp. Its almost rounded off, and does a great job of melting the plastic and not scratching the skin.

I had asked the forum about those last 4 remaining holes on the HS-00001 doubler, and it seems the consensus is that all the pre-punched holes on the doubler needs to be back-drilled into the spar and spar bar. So I drilled those out tonight and deburred them. Heres that thread for reference: http://www.vansairforce.com/communit...d.php?t=143576

I also spent a little time practicing removing rivets from my practice kit. These kits are pretty handy! I have done a couple and I always find myself using them as "experiment pieces" months after I had completed them. I didn't take any photos of this since its not really relevant to the build. It was just me trying to work on drilling out rivets.

Heres a few photos from tonights work. There's not many, since there really isn't much to show: https://goo.gl/photos/ZDRwZgKYnNYLB6nUA

I am going to pick up a few tools to make things go a little faster:
1. Electric screwdriver for deburring
2. 1/4 adapter for deburring bit: http://www.cleavelandtool.com/HEX-AD...ductinfo/1095/
3. Movers blankets


My goal is to do the same to the right horizontal stab, and then move on to dimpling. If the weather holds up, and I get all these parts ready, I plan on spraying them with AKZO this weekend.
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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 : 11-10-2016 at 10:48 PM.
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  #14  
Old 11-13-2016, 10:59 PM
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CubedRoot CubedRoot is offline
 
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Default November 13th, 2016. 3 hours

The Dixon household has caught whatever sinus bug that has been going around, and then add onto that the horribly smokey air quality from all the wild fires makes for little motivation to work on the plane. But I did get to feeling a bit better today, and the baby is at "Nana's" house so tonight was a good work night.

I worked about 3 hours finishing up the metal prep for the right horizontal stabilizer. I deburred and dressed all the edges of all the parts remaining for both horizontal stabilizers. I also finished up the HS-710 and HS-714 as well as the HS-609PP rear spar bars. I decided to remove just the blue plastic around the rivet lines on the external skin surface to help keep them protected during storage. However, all of the internal parts have had the plastic removed.

I will finish these parts up by dimpling everything and then scuffing and cleaning them for priming. I still haven't decided if I am going to dimple the skins BEFORE or AFTER priming. The skeleton I am going to dimple before scuffing/priming. But the skin will be much, much easier to scuff and clean if its inside is free of dimples, but I might have to issues dimpling after its primed. We'll see.

Thats all for tonight. Heres the photos of tonights work: https://goo.gl/photos/wFQ8iA6csKsPwUxZ8
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Tail kit Completed - March 2017
Wing Kit Started - June 2017
My Build Log: http://www.theskunkwerx.com

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  #15  
Old 11-14-2016, 09:50 PM
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CubedRoot CubedRoot is offline
 
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Default November 14th, 2016. 2 hours

Tonight was just finishing up the metal prep work in advance of priming. I ended up getting all of the substructure dimpled and ready for cleaning and priming. I mostly used my DRDT2 to dimple the parts, since its so convenient and easy to use. But, it just won't get in to some of the hard to reach holes around the corners of the parts and the noses of the ribs. So, I had to fire up the squeezer for those few remaining tight holes.

There were a few holes that were too close to even fit my squeezer, especially on the HS-706 rib. Luckily I had just the tool for that:



This pop-rivet dimple set worked very very well, and its worth every penny! I had never used one before, but figured it couldn't be too bad, so I gave it a go without trying a test piece first. It took a few tries of starting out gently squeezing, and moving to progressively firmer squeezes with the pop-rivet tool, but after the first one I realized that the nail "mandrel" could take a good bit of pressure. I kept dropping in a AN4263-4 rivet to check the dimple to make sure I had it flush enough. After a few tries I learned how to have good results like this one on the first squeeze:



One foot note: While attempting to dimple the bottom flange on the rear spar, I realized I didn't match drill the entire bottom flange, because my dimple die would not fit in the hole. Whoops :-) But it was an easy fix. I just re-clecoed the spar to its married skin, and matched drilled the holes. Then re-deburred the holes in the skin and spar, and proceeded to dimple as normal.

Not many photos from tonight since there isn't a lot to capture during dimpling, but heres what I took: https://goo.gl/photos/XBrdgZvJTqFzhiGP7
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RV-7 Slider -
Tail kit Completed - March 2017
Wing Kit Started - June 2017
My Build Log: http://www.theskunkwerx.com

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  #16  
Old 11-16-2016, 01:04 AM
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CubedRoot CubedRoot is offline
 
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Default November 16th, 2016. 2.5 hours

Tonight I figured I would start on the vertical stabilizer. I have both my horizontal stabilizers ready for scuffing/cleaning and priming, but I don't want to do that until a few hours before I am ready to prime. With my work schedule running until 5pm, and getting dark at 5:30, I just don't have the time to setup for priming during the week. So, I am planning on doing that this weekend.

In the meantime, I figured I might as well start the vertical stabilizer, so I can have it ready for priming at the same time I do the horizontal stabilizers and save some time and mixing, and do them all at once.

The vertical stabilizer was actually really easy to assembly and get ready for metal prep. I don't know why Van's doesn't start the kit with this piece since its so easy to do.

I first started out by assembling the VS-808PP and VS-803PP. Then I clecoed on the hinges VS-410PP, VS-411PP and VS-412PP to the rear spar assembly. Once assembled I match drilled everything to a #30 except the very bottom holes in the bottom hinge, which will be drilled during the fuselage assembly.
After that, I fluted and prepped the VS-404, VS-405, VS-406, and VS-407 ribs and assembled them to the rear spar. Oddly enough, the instructions didn't say exactly to also assemble the VS-702 front spar but I took it as a given since Van's called for the skeleton to be assembled. Once I had everything assembled, I ended up with a nice looking skeleton for a Vertical Stabilizer! I then match and final drilled all the assembly's as called for with a #30. This is what it looks like:



Next, Van's called to cleco on the VS-801PP skin to the skeleton. This skin went on much more easily than the horizontal stabilizer skins! I double checked everything was in alignment and clecoed both sides together, skipping a hole between clecos. I decided to only remove the blue protective plastic from the inside of the skin so I get a good fit and proper alignment against the spars and ribs (which I had also removed the plastic from). It will be scuffed and primed in the future anyways.

Once the skin was cleco'd down, I matched drilled everything using the smaller #40 drill bit in all the skin punched holes. I had previously marked all my parts with a sharpie, and noted their orientation so I would be good to go when I disassemble the stab for priming. Here is how it turned out:



That's about all I could get done tonight. In 2.5 hours I completed the drilling and assembly of the entire vertical stabilizer! This is a good place to stop, and tomorrow I will pick up by disassembling everything, making sure its all marked, and then deburring, edge finishing, and dimpling all the parts to prepare them for priming. I will get the vertical stab primed up with the other parts this weekend.

Here's a link to the full album of tonights work: https://goo.gl/photos/1BmasXXJaBHai3Ko7
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Tail kit Completed - March 2017
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My Build Log: http://www.theskunkwerx.com

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  #17  
Old 11-16-2016, 10:48 PM
atalla atalla is offline
 
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Location: Whistler BC
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Default Im right about where your at!

Hey Lynn looking good. I just finished the VS and I'm all ready to put the HS together.

Ordered some parts for the Elevators.

great blog.
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  #18  
Old 11-16-2016, 10:50 PM
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CubedRoot CubedRoot is offline
 
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Default November 16th, 2016. 3 hours

Tonight I mainly focused on metal prep on the vertical stabilizer. I disassembled the stab, and then deburred all the holes. Then I marked which holes on the VS-808PP doubler and VS-803PP rear spar that needed to be countersunk / dimpled. I used my DRDT-2 dimpler to set the dimples in the VS-803PP, and then used a micro-stop countersink cage to machine countersink the holes for in the spar doubler. After a few test fits to make sure those two parts fit flush with each other, I moved on. It came out pretty good:




I then removed some strips from the rivet lines on the skins so I could deburr the skin, as well as removing all the remaining plastic from the other parts. I also finished the edges of all the lightening holes in the ribs and doublers. Tomorrow I will work on finishing the edges of all the pieces and then dimpling the skeleton, then it will be ready for cleaning and priming this weekend.



Not a lot of photos, since there really wasn't much to take photos of, but here's the photos from tonight work: https://goo.gl/photos/Ah54BATLQMPghYVg7
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Tail kit Completed - March 2017
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My Build Log: http://www.theskunkwerx.com

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  #19  
Old 11-16-2016, 10:54 PM
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CubedRoot CubedRoot is offline
 
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Quote:
Originally Posted by atalla View Post
Hey Lynn looking good. I just finished the VS and I'm all ready to put the HS together.

Ordered some parts for the Elevators.

great blog.
HAH! We must have been typing up our posts at the same time. I just entered another post for my progress tonight.

Have you noticed that the VS is much easier to complete than the HS? I wonder why Van's doesn't have us start on it at first. Seems like the VS would be a great confidence builder for a first time builder, and you come out with a finished sub assembly pretty quickly.

I know one thing.... I DEFINITELY need to find some sort of powered screwdriver to run the deburring bit. My hands are so sore from spinning the wobbly screwdriver thing :-)
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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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  #20  
Old 11-18-2016, 12:47 AM
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CubedRoot CubedRoot is offline
 
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Default November 17th, 2016. 3 hours

Tonight I simply finished up all the metal prep work on the vertical stabilizer. I deburred all the holes, and then finished all the edges on the ribs, spars and skins. The spar doubler I spent a good bit of time on getting it smooth since its a heavy piece of aluminum. I started on my bench grinder to break the edges, and then finished them off on the scotchbrite wheel. I used a deburring tool to round off the edges of the lightening holes and then use a scotchbrite pad to smooth those down. It came out smooth:


Then I finished up the night by dimpling all of the holes, while skipping the ones destined to have nutplates for the fiberglass fairing. I used the DRDT2 for most of them, and the squeezer for a few, and finally the pop rivet dimple die set for those last two in the nose rib.

That wrapped it up for the night. I don't have any work backlogged on my bench because I am waiting on this weekend so I can scuff, clean and prime the horizontal and vertical stabilizer parts/skins. I am spraying outside, so I need a day with plenty of daylight.

Only a few photos from tonights work, since it was mainly metal prep. Heres what I took: https://goo.gl/photos/kEVxThYQk7GBvHFf6
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Tail kit Completed - March 2017
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My Build Log: http://www.theskunkwerx.com

VAF Donation paid for 2017
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