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  #61  
Old 12-11-2017, 11:40 AM
kiljoy's Avatar
kiljoy kiljoy is offline
 
Join Date: Sep 2014
Location: San Francisco
Posts: 97
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Hi everybody,

So I received a new supply of tank sealant from Vans and continued on with the left fuel tank.
Here is a snap of the fuel sender temp installation into the tank. That wire holding the float in place is STOUT.



Here's the outside shot of the tank. This is all presealing of the attach bracket and the inboard rib.



The sender is now sealed into the tank, the attach bracket and rib are in and the vent line connection is both torqued in and sealed. Now I play the waiting game until at least Wednesday. After that I'm going to beef up the tank cradle to withstand the weight of 25 gallons of water for leak testing.

My flying club's Christmas party was Friday night and I thought about making punch and dispensing it from my fuel tank but I thought that tank sealant might leave a slight aftertaste. Bitter... like anise. Anyways common sense got the better of me.

Anywho, here are the latest video feeds of tank work AND building of some EAA workbenches! Yes!! I finally got around to building a couple of them to replace the craptastic folding tables in our hangar. Once the locking casters get put onto the bottom they'll be perfect.

https://youtu.be/zztZG3AhMts
https://youtu.be/DwnFI6vlQes
https://youtu.be/WRJw39hmO9w
https://youtu.be/aM6cn8UF8BE

- Kilroy
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  #62  
Old 12-18-2017, 01:16 PM
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kiljoy kiljoy is offline
 
Join Date: Sep 2014
Location: San Francisco
Posts: 97
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Hi everybody,

Since we last spoke the tank sealant has cured enough that I felt comfortable filling it up with
water and leak testing it! Our hangars only have a couple of places with a water hose so it was
off to the plane wash and hauling over 4 gallon jugs of water. I filled the tank up just waiting
for some kind of comedic spout of water to start shooting out sideways like a broken dike.
Thankfully nothing like that happened. The only place the tank leaked was out of the overflow
vent spout (because I didnt have an appopriate cap nut) and from the fuel cap. I'm not worried
about leaking from the fuel cap as I won't be doing inverted flight very much.

While waiting for the sealant to cure, instead of going onto the next fuel tank I've decided to take
a break from ribs and sealant and start working on the main spar. Of course in order to do that
I had to build a couple of work benches as the one i have is nice but not near large enough to
satisfy the space requirements of the spar. Anywho, after I made those I got to the j-channel
fabrication then the tank nut plates. Drill, baby, drill! Here are some pics from the last couple weeks:






And as always here are the video feeds from that work. Enjoy

https://youtu.be/DwnFI6vlQes
https://youtu.be/WRJw39hmO9w
https://youtu.be/aM6cn8UF8BE
https://youtu.be/qu93relRUyY
https://youtu.be/VQwrbJOARUU
https://youtu.be/TRtOaQrfJi8
https://youtu.be/Jh2E7pp2_7U
https://youtu.be/JaL21AynklM
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  #63  
Old 12-18-2017, 01:34 PM
Carl Froehlich's Avatar
Carl Froehlich Carl Froehlich is online now
 
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Location: Dogwood Airpark (VA42)
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Default You do not want the fuel cap to leak

Adjust the seal on the cap as needed (loosen the locking nut, then turning teh bottom disk, and retighten the locking nut).

You donít want water getting into the tank when sitting on the ramp in the rain.

Carl
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  #64  
Old 12-18-2017, 04:13 PM
kiljoy's Avatar
kiljoy kiljoy is offline
 
Join Date: Sep 2014
Location: San Francisco
Posts: 97
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Quote:
Originally Posted by Carl Froehlich View Post
Adjust the seal on the cap as needed (loosen the locking nut, then turning teh bottom disk, and retighten the locking nut).

You donít want water getting into the tank when sitting on the ramp in the rain.

Carl
Very true. I'll adjust it tomorrow and refill the tank.
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  #65  
Old 01-14-2018, 11:59 AM
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kiljoy kiljoy is offline
 
Join Date: Sep 2014
Location: San Francisco
Posts: 97
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Okay so the holidays are over finally and it's time to get back to work on the plane!!! Over the holidays
I had a nice time back home in the south with my dad and siblings. I shot a couple of deer, drank a lot
of wine, etc etc

Anyways back to the important stuff. As suggested to me by Carl Froehlich I had adjusted the fuel cap
on the left tank, refilled the tank and tested again for leaks. This time no dribbling of anything from
the fuel cap so its all happy there.

One of the VAF members, Mikeandmaz, came in from over the pond to check out the build and get his
hands dirty. I'd been kind of putting off riveting the back baffle and attach Zee's to the left tank. It
was really nothing more than silly fear. I knew what it meant to have to open up the baffle to get inside.
Once sealed up that was it, theoretically anyways.







I put the fuel sender float on the inside, we cleaned the inside out thoroughly with lint free clothes, and
commenced to clecoing the baffle on. Together Mike and I riveted the baffle then attach Zees in place.
Once that was done nothing to do but wait. The sealant should be dry tomorrow. At that point
all I need to do is go back, countersink and rivet the remaining baffle rivets and that SHOULD be it.
After that seals it's the balloon test and when that passes I'll call it done.

With the tank in waiting I turned my attention back to the main spar and the ribs. I took an hour and
shored up one of the work benches. Note to self but the next time I build a set of the EAA work benches
I'm going to buy 2 extra 2x4s and use those as the source for the 33" pieces. The original 4 used are
going to stay full length. 8' tables are much more useful. Also I've started re purposing one of my ram
mounts to use to help me document my build.



Anyways, The ribs have been fluted, flattened, final drilled, deburred, dimpled (bottom flange only),
primed, step drilled, bushings put in and are riveted to the main spar itself!



And of course the obligatory through the ribs pic:



It's making me nervous though as now the ribs are held onto the spar with nothing but rivets and
a couple of bolt/washer/nut combos. Once I get the rear spar on I'll feel a little more comfortable.

Anyways here's just a few links to the video feeds that have been put up. There's a lot of them
so I'm only linking a few. Enjoy.

https://youtu.be/ELeL0lj1FrI
https://youtu.be/i9HqQp1sMn0
https://youtu.be/-PPBZVfI9r4
https://youtu.be/va90x4sRjy4
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  #66  
Old 01-25-2018, 08:29 PM
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kiljoy kiljoy is offline
 
Join Date: Sep 2014
Location: San Francisco
Posts: 97
Default Rear Sparring

Hi all,

So I've been lucky and have had an over abundance of time the last couple of weeks to work on the left wing a little bit more. I've gotten the ribs on, the rear spar on along with the aileron hinge brackets and today got about 50% of the top skins on.

I'm so glad that I built those two work benches and even happier that I kept the tops of them at 8' long.

Here is a pic of the left wing with the rear spar having been riveted on and the top skins cleco'd in place. I'd left the J channels in place to test the fit. They hadn't been primed yet:



Here's the opposite direction. I'm very happy with the way it fit. I just made sure to support the main spar as it's laid out down the workbench to maintain a straight spar.



Afterwards I test fit the ailerons and flaps just to make sure it looked well. I have to admit they fit better than my elevator trim tab does:



I should be finalizing the top skins tomorrow then I'm moving onto the leading edge. I need to order a PAR 36 LED light for the landing light still. Any suggestions?

Here are some of the video feeds from the rear spar. Enjoy:

https://youtu.be/wgrdKX89tos
https://youtu.be/aKpA-Ed5Vbk
https://youtu.be/Jahi1HU6lbk
https://youtu.be/RDawJrSeUqE
https://youtu.be/kFl42dh6pWI
https://youtu.be/VjQ6n9LarPE

- Kilroy
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Last edited by kiljoy : 01-28-2018 at 08:42 PM.
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  #67  
Old 10-21-2018, 07:31 PM
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kiljoy kiljoy is offline
 
Join Date: Sep 2014
Location: San Francisco
Posts: 97
Default Let there be LIGHT

Its been 9 months since my last post. A lot has gone down since then:

Lost my job in January along with my entire team. That one sucked. I wasn't even in the office the day it happened. I had members of my team texting me around 10:30am mostly containing expletives. The details are fuzzy mostly due to a non disparagement clause in my release contract.

Afterwards I took a few months off to catch up my right wing to match the left. It was a nice break. I got to spend more time with my wife, my kitties. I got to be at the airport everyday making sure the club planes were happy and flying well.

Around June I realized that I needed to get back into the working world. I didn't need more time off... I needed to get back to running a software team and making good product. Plus... fuselage kits, engines and things don't pay for themselves you know!

Here's a rundown of all the things I've learned in the last 9 months of plane building I didn't know before:

- Right wings are just as difficult as left wings.
- Just because you practiced with tank sealant doesn't mean your other tank will be any prettier or less messy!
- Fiberglass, wiring, etc... its all a piece of cake (if you go slow, practice and do it right)
- Wiring... okay so wiring is in itself easy but if you want it to actually be clean and work well it gets complicated.

I got around to finally wiring up my Fly LED lights and making the breakers, switches, etc work. Gotta say I love them. I had to rewire it about 10 times to make sure all of the wires in the connectors were wired up correctly. Never blew any circuits and didn't ever see any smoke but it wasn't like I didn't try!

Anyways, there's more I'm sure but I wanted to just post a few pics of the fun:








Notice the victory stance and the arms raised... I was praying to some
sort of god... not sure which one.

Fly safe,

- Kilroy
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  #68  
Old 10-23-2018, 08:38 AM
engineerorange engineerorange is offline
 
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Location: Catawba, NC
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Default keep plugging away

My RV project saw 3 jobs and 1 wife go away. 2 of the 4 were my choice, 2 were not. But the RV gave me something to always strive for and something to occupy my hands and my mind when they needed it.

IT WAS WORTH IT!! Don't give up the good fight.
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  #69  
Old 10-23-2018, 09:08 AM
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bkervaski bkervaski is online now
 
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Awesome. Havn't even got my plane back from paint yet and already want to build another one LOL.
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  #70  
Old 10-23-2018, 04:33 PM
sblack sblack is offline
 
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I built the flyleds kit too. There was nobody more surprised than me when it all lit up first time! I am still a year (bwahaha) from flying but an RV10 on my field has the same lights and I saw him arrive in the evening and they looked great. I don't think there is a better value for nav/strobe lights. And building stuff is fun. The guy (Paul?) is very helpful and fun to deal with too. He seems to be one of us.

My project is a 1990 era RV4. The guy had it for 25 yrs, 3 moves and 2 marriages. So it is a familiar story. These things do take over your life. I got it as an empty shell. Heck, 6 months to hang an engine and put some gauges in and I'll be flying. That was in 2014. I'm a bit wiser now. In fairness, my hangar is 45m from my house so it only sees me on weekends. That makes a huge difference in build time. But I don't have a garage so there is nothing I can do about that. You do what you can.
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