Project: kcolgan   -  
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Builder Name:Kent Colgan   -  
Project:   Vans - RV-9A   -   VIEW REPORTS
Total Hours:437
Start/Last Date:Sep 24, 2019 - No Finish Date
Engine:Lycoming IO-320
Panel:AFS EFIS, BOM backup, FlyOnSpeed AOA
 
Friendly URL: https://eaabuilderslog.org?s=kcolgan

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May 09, 2024     Building the Wing - Priming       Category: Wings
Deburred dimpled and primed the right wing bottom skin. Deburred all of the holes in the wing sub structures.


 
May 08, 2024     Building the Wing - Priming       Category: Wings
Primed the left wing bottom skin and started deburring the right wing bottom skin.


 
May 06, 2024     Building the Wing - Pitot       Category: Wings
I drilled the pitot mast to the spar flange. I fabricated an L bracket and drilled it to the mast and wing rib. I deburred and dimpled all of the left bottom skin rivet holes.


 
May 05, 2024     Building the Wing - Pitot Tube       Category: Wings
Cut a hole in the left wing bottom skin for the pitot tube mast and drilled holes for mounting the.mast to the skin


 
May 04, 2024     Building the Wing - Aileron & Flap Gap Fairings       Category: Wings
Deburred, dimpled and primed the aileron & flap gap fairings.


 
May 02, 2024     Building the Wing - OAT Probe       Category: Wings
Decided to mount the temperature probe on the mid access panel on right wing and drilled the mounting hole.


 
May 02, 2024     Building the Wing - Lidar       Category: Wings
Hooked up the Lidar device to 12 volts and confirmed that it operates correctly and can be communicated with via wifi.

https://youtu.be/gbh6zx2tZXk?si=SoG5o0kTz6RQUaXR

https://youtube.com/shorts/6zVDPZLP1ZI?si=TbG-q6SiMkmWNEMs


 
Apr 30, 2024     Building the Wing - Lidar       Category: Wings
Customized the left wing outboard access panel to mount the lidar-based landing height system (Lidar altimeter).


 
Apr 27, 2024     Building the Wing - Bottom Skin       Category: Wings
Lots of reaming today on the bottom skins and the aileron and flap gap fairings.


 
Apr 26, 2024     Building the Wing - Skin Prep       Category: Wings
On the two bottom skins I reamed the holes that line up with the main spar, deburred and dimpled them. Clecoed the skins and started reaming the rest of the holes


 
Apr 25, 2024     Building the Wing - Wing Stand Mod       Category: Wings
I modified my existing wing stand to allow the removal of the fuel tanks and to enable the stand to support the wings with the tanks removed.


 
Apr 23, 2024     Reviewing Rewriting Instructions       Category: Wings
I've completed a detailed pass through the wing build instructions, identifying the items not completed by the quick builders. I then compiled all the things that must be done into my own instruction set (Rev 0 is attached). Some areas need more detail (e.g., pitot tube install), but this will get me started.


 
Apr 18, 2024     Reviewing Wing Instructions Category: Wings
As recommended by Vans I'm walking through the wing building instructions and confirming that the step was performed or is something I need to do.
 
Apr 18, 2024     Finishing the Forward Fuselage       Category: Fuselage
More parts primed / riveted and where needed, topcoated. "8.24 Finishing the Forward Fuselage" instruction set is now complete (attached). Vacuumed the shavings and other debris out of the fuselage and covered it up while I work on the wings.

Note that I skipped "8.21 Wing/Fuse Assembly", "8.22 Cabin Systems", and "8.23 Fitting the Empennage" because the wings aren't done yet, so I'm not finished with Section 8 yet.


 
Apr 14, 2024     Finishing the Forward Fuselage       Category: Fuselage
I've been working on the aileron trim. Done except for priming.

I've also been priming the parts for the instrument panel area including the map compartment.


 
Mar 29, 2024     Finishing the Forward Fuselage       Category: Fuselage
Finished fitting the left panel support in its new position. Attached the truncated support to the sub panel with two angles.


 
Mar 28, 2024     Finishing the Forward Fuselage       Category: Fuselage
Placement of the EFIS screen in front of the pilot required that the left panel support be moved left a bit.


 
Mar 17, 2024     Finishing the Forward Fuselage       Category: Fuselage
Increased clearance in the sub panel and forward canopy deck, per plans.


 
Mar 16, 2024     Finishing the Forward Fuselage       Category: Fuselage
Working on the "map box". It was an optional item but I think a good idea. There is not any other convenient place in the cabin to store misc little stuff. Had to cut a hole in the sub panel and trim off some of the right fwd canopy deck (per plans).


 
Mar 16, 2024     Finishing the Forward Fuselage       Category: Fuselage
Primed the top skin with SEM self etching primer.


 
Mar 07, 2024     Finishing the Forward Fuselage       Category: Fuselage
Continuing to work on the panel structure. Drilled the forward canopy deck to the longerons. I'll use Cherry Max rivets on the aft two holes in the forward canopy decks due to poor access for bucking bar.


 
Mar 01, 2024     Finishing the Forward Fuselage       Category: Fuselage
Match drilled the top skin to the firewall.


 
Feb 22, 2024     Finishing the Forward Fuselage - Panel Assembly       Category: Fuselage
Made more parts for the panel structure.


 
Feb 14, 2024     Finishing the Forward Fuselage       Category: Fuselage
Primed and topcoated the roll bar and support channel.


 
Feb 13, 2024     Finishing the Forward Fuselage       Category: Fuselage
Riveted the bulkhead gussets and riveted the F-709 bulkhead in place.


 
 
Feb 09, 2024     Finishing the Forward Fuselage - Priming       Category: Fuselage
Continuing to prime lots of parts. The latest is the two top skins. The most forward rear top skin is visible in the Cabin so I used Dupli-Color self-etching primer on the visible part and top coated it after primer was well cured (3 days at 75 degrees)


 
Feb 09, 2024     Finishing the Forward Fuselage - Panel       Category: Fuselage
Made some angle brackets for the backside of the panel. Making the curved one from 3/4 x 3/4 x 1/16 angle was time consuming hand work.


 
Feb 08, 2024     Big News for My QB Wings       Category: Laser Cut
Van's finally sent me a specific report for my QB wings. My wing kit only included one LCP: "Access Hatch Doubler" VA-195C. This part is categorized as "Acceptable for Use" but since a) it only costs $5.51, and b) I don't think it's even installed yet, I ordered a replacement. So in conclusion, my wings will have no LCPs at all.


 
Jan 30, 2024     Finishing the Forward Fuselage       Category: Fuselage
See photo below. I managed to drill these two holes too high by about 1/8". You can see a sliver of the holes in the rib on the other side. Same issue on the right side. This happened because I placed the shim (second photo) under the rib then match drilled the offending holes. The shim should have been on the top.

I talked with Mike and came up with a plan. I'll install rivets in the bulkhead (shallow countersink on both sides), shave them flush on both sides, and make a doubler patch for the aft side using 43.13 as a guide (see pdf). The rivets will fill the void of the misdrilled holes. A test on scrap showed that the rivet expands into the slight countersink and after shaving, holding the remaining rivet material securely in place (see photo of test piece).


 
Jan 28, 2024     Finishing the Forward Fuselage       Category: Fuselage
Using my new #19 reamer and taking lots of care to polish the holes, I successfully dimpled the four holes for #8 screws with no cracking.

Dismantled all the parts that need priming and/or dimpling Cleaned up and primed a bunch of little parts (SEM).


 
Jan 26, 2024     Cracked #8 dimple       Category: Van's Q&A
One of the cracks exceeded the acceptance criteria so I replaced the skin.


 
Jan 26, 2024     Finishing the Forward Fuselage - Replacement skin       Category: Fuselage
Finished clecoing the replacement top skin in place. It fits really well, actually I think it fits better than the original, strangely. I'm waiting for my number 19 reamer to come from aircraft spruce so that I can properly prepare the four holes in the skin for number 8 dimples.


 
Jan 25, 2024     Finishing the Forward Fuselage - Replace Skin       Category: Fuselage
Match reamed the replacement skin using the original skin. Filed and sanded the edges. Deburred the holes. Started checking the fit.

Fit up and drilled holes for installing the ADAHRS mounting bracket.



 
Jan 23, 2024     Finishing the Forward Fuselage - Roll Bar       Category: Fuselage
I drilled the six holes on each side of the roll bar into the mounting brackets. Countersunk the four on each side that needed to be countersunk. Threaded the two on each side that needed to be threaded for number 8 screws.

I dusted off the spare top skin that I had which when delivered had a small bend in it and vans replaced. I fixed the bend and now it's as good as new. I removed the top skin that has the cracked dimple and have started to line up that top skin as a template to ream the new skin.


 
Jan 21, 2024     Finishing the Forward Fuselage - Roll Bar       Category: Fuselage
Well, rats. I dimpled the top skin for #8 screw where it attaches to the roll bar and one of the dimples cracked. Sent a question to Van's support. That was the first of 4 #8 dimples. When the first one cracked, I polished the remaining three with 600 grit sandpaper before dimpling and they didn't crack.

The next day Vans sent me an acceptance criteria based on the length of the cracks. One of the cracks is too long.


 
Jan 20, 2024     Finishing the Forward Fuselage       Category: Fuselage
Fitting up the roll bar brace and roll bar. Drilled and reamed aft rivet holes and most of the forward holes on the brace.


 
Jan 19, 2024     Finishing the Forward Fuselage - Roll Bar       Category: Fuselage
Left and right side mounting brackets are final reamed and the overhang is ground away to the contour of the longerons.


 
Jan 17, 2024     Finishing the Forward Fuselage       Category: Fuselage
Left side roll bar mounting bracket drilled/reamed for bolts.


 
Jan 14, 2024     Finishing the Forward Fuselage - Roll Bar       Category: Fuselage
Set the width of the support brackets for both sides and riveted them together after priming the surfaces in contact


 
Jan 13, 2024     Finishing the Forward Fuselage - Roll Bar       Category: Fuselage
Finished riveting the roll bar components together. It's about 180 rivets. Drawing called for installing CS4 blind rivets on the aft channels and 426 rivets on the forward channels but of course I got it backwards. No harm done though. Disassembly is very rigid.


 
Jan 10, 2024     Jan 9 2024 Engineering Summary Category: Laser Cut
A thorough presentation of testing performed, findings and conclusions regarding LCPs by Van's engineering. The key finding is that “manufactured cracks” (those formed while dimpling some LCPs) are in a compressive stress field after riveting. This was proven by a pretty exhaustive series of fatigue tests with the manufactured cracks at various orientations relative to the cyclic stress field during testing, and various orientations relative to the material grain. This is huge news because it showed that manufactured cracks don't propagate under cyclic loading. The presentation also made clear that their conclusions and recommendations are very conservative (they based the testing on the single highest rivet load even though all other rivets' loads are much lower, they assume 50% aerobatic and 50% flight school loading profiles, apply a factor of 1/3 on predicted life). Although some parts are recommended for replacement in an “abundance of caution”, even those parts really don't need to be replaced.

https://youtu.be/O-W4WH57qW0?si=lMHAQFqcSxNReOgS

Some giants in the industry weigh in on the engineering summary.

https://youtu.be/26-2g-rgkLo?si=y36T7jN8Vc1ZImNe
 
Jan 08, 2024     Rev 7.2 of LCP List       Category: Laser Cut
No change impacts me


 
Jan 08, 2024     Finishing the Forward Fuselage - Roll Bar       Category: Fuselage
Primed the roll bar parts with rustoleum self etch. I only sprayed the interior surfaces and countersinks of the channels. After riveting and additional fit up, I'll final prime and topcoat the exterior. Note that the panorama photo software that splices the photos together makes the long strips look something other than straight. They are in fact straight with parallel edges.


 
Jan 08, 2024     Jan 7 2024 Van's Email       Category: Laser Cut
Received this email from Van's describing their plan for resolving the laser cut part problem. They also updated the list of parts but it doesn't look like there were any changes for the RV9A.


 
Dec 27, 2023     Finishing the Forward Fuselage - Roll Bar       Category: Fuselage
Used my trusty homemade flange straightener to straighten the flanges of the aft channels. Laying out the channels trying to figure out whether to trim the bottom ends or the top ends to get the right height and width.


 
Dec 26, 2023     Finishing the Forward Fuselage - Roll Bar       Category: Fuselage
I finished making a series of parts for the roll bar. Also cut two large holes in the rear roll bar channels.


 
Dec 22, 2023     Nov 10 2023 Update       Category: Laser Cut
Van's has changed the "First Date in Inventory" for a number of critical parts in the RV9A wings to 5/20/2022. VA states in the attached summary that this is the date that vendors were first directed to fabricate LCPs so is very conservative. Nonetheless, this date precedes the date that my wings were complete and ready for shipment by Exemplar (6/2/2022). Consequently, I can no longer conclude that my wings have no critical LCPs.


 
Dec 17, 2023     Finishing the Cabin Interior       Category: Fuselage
I installed the wear blocks on the baggage compartment bulkheads (they wear against the shoulder harness cables which pass through the bulkhead).

With that, I've completed this instruction set ("Finishing the Inside of the Cabin, Rev 2"), except for Step 1.e which I've added to the "Parking Lot".


 
Dec 12, 2023     Finishing the Cabin Interior - POS-12       Category: Fuselage
I finished the final installation of the flap position sensor. It works as it should and the range of motion is not exceeded when the flaps are put in their extreme positions.

https://youtu.be/SfAvvJhqZmI?si=pGWrOECXwE4Ou4qm

I also top coated the baggage compartment bulkheads.


 
Dec 10, 2023     Finishing the Cabin Interior       Category: Fuselage
I deburred and prepped the baggage compartment bulkheads and primed them with Dupli-Color self-etching primer.


 
Dec 09, 2023     Finishing the Cabin Interior -       Category: Fuselage
Deburred and primed (SEM self etch) the plate attaching the POS-12 linkage to the flap actuator. Added lock nuts to the linkage and also used locktite on the black connectors.

I had to remove both D bolts from the gear mounts in order to rivet the plate nuts. The attached table shows the torque values used to reinstall the bolts. Used new nuts.


 
Dec 08, 2023     Finishing the Cabin Interior - POS-12       Category: Fuselage
Made progress on the POS-12 linkage. Tested to ensure that from full retraction to full extension the POS-12 range of movement is correct. It is.


 
Dec 06, 2023     Finishing the Cabin Interior - Gear Mount       Category: Fuselage
Finished installing and torquing the right main gear mount. I had forgotten to add the shimming washer for one of the bolts and had to make a washer placement tool. It holds the washer just well enough to place it without dropping it, but once the bolt holds it in place, a little tug on the tool releases the washer. The as-built torque values are shown in one of the attached photos.


 
Dec 05, 2023     Finishing the Cabin Interior - Gear Mount       Category: Fuselage
The third time was a charm. I installed the left gear mount using new nuts and in most cases new bolts (inspected all before installing), and torqued all of the bolts. Before doing this I spent a lot of time measuring the thickness of each joint to be bolted and calculating the appropriate bolt length / washer combination. I did this to double-check and document those combinations that I had determined previously on-the-fly. The attached photos of the calculation pages document what was done.


 
Dec 03, 2023     Finishing the Cabin Interior - Gear Mount / POS-12       Category: Fuselage
Mounted the POS12.

A frustrating afternoon. After torquing a bunch the bolts holding the gear mount I discovered an interference between a rivet and the mount. Had to uninstall the bolts, several of them really tough to access. Filed a notch in the mount, reinstalled, and it still interfered! Had to do it all again. Still have to reinstall the mount.


 
Dec 02, 2023     Finishing the Cabin Interior - Gear Mount / POS-12       Category: Fuselage
Torqued the AN4 bolts to the main spar installing the left gear mount. For each I measured the drag torque and added it to 60 in lb to determine torque wrench setting. The bolt length and washers specified on the drawing didn't always leave enough excess threads so needed to adjust. See my instructions for details.

I installed the POS-12 platform with double-sided tape and the 4 screws.


 
Dec 01, 2023     Testing UPDATE       Category: Paint / Decals
I wanted to see if there was any difference between Dupli-Color self-etching primer and Rust-Oleum self-fetching primer. So I made a couple of coupons. The first one I allowed the primer to cure for a day before topcoating and the second one I allowed the primer to cure for 2 days before top coating. First, the performance of both of them was at least as good as the performance of the dupliColor coupons. Secondly, there may have been a little less disbondment on the reverse bend with the coupon that cured for 2 days, but there is really not much of a difference. Conclusion: I can use rustoleum self etching primer.


 
Nov 30, 2023     Torque Wrench Check       Category: Tools
Before installing the gear mounts I wanted to make sure the torque wrench was accurate. It's very close.


 
Nov 27, 2023     Finishing the Cabin Interior - Gear Mount       Category: Fuselage
Topcoated the flap actuator covers, tunnel cover, and a couple of other covers from the cabin.

Also countersunk the 4 holes on each side that are used to install the gear mount.


 
Nov 26, 2023     Finishing the Cabin Interior - POS-12       Category: Fuselage
Continued fitting up the platform for the POS-12. Finished drilling holes, sanded, and primed the wood platform. Cut 4 number 8 screws to custom length for mounting the platform.


 
Nov 24, 2023     Finishing the Cabin Interior - POS-12       Category: Fuselage
Making an oak platform for the POS-12.


 
Nov 22, 2023     Finishing the Cabin Interior - Flap Actuator / Gear Mount       Category: Fuselage
Mounted the actuator in it's support and installed the support in the fuselage. Bolted and safety wired the bottom end of the actuator to the actuator arm as required by the plans. Installed the seat back brace support in the fuselage and attached the show planes controller. The blue tape in the pic shows the position of the arm with flaps fully extended and fully retracted. Need this to figure out where to mount the POS-12 position potentiometer.

I touched up the paint in the forward fuselage in area damaged while fitting up the gear mounts, and earlier in the build on the side skin while riveting. Unfortunately, I reapplied a second coat outside the allowed window (within an hour or after 48 hrs). Now I know what happens if you don't follow that instruction: the paint bubbles up. I'll have to let that cure for days then sand it off and try again. What a pain.

I primed and topcoated the gear mounts.


 
Nov 17, 2023     Finishing the Cabin Interior - Gear Mount       Category: Fuselage
Removed some interferences and fit up the right gear mount. Match drilled and reamed the holes in the mount.


 
Nov 14, 2023     Finishing the Cabin Interior       Category: Fuselage
Topcoated the seat backs and the flap actuator supports with Rustoleum satin enamel.

Continued fitting up the left gear mount. Drilled some holes. More to do.

Received the POS-12 flap position sensor and measured the resistance vs position to determine the size of the dead zone at each end of the range of motion.


 
Nov 13, 2023     Finishing the Cabin Interior       Category: Fuselage
Abraided and touched up the primer in the seat backs and the actuator supports.

Cleaned up and fit up the left and right main gear with the gear mounts. Reamed the upper bolt hole that holds the gear leg in place within the mount to final size, and deburred the mounts and legs. Reamed all of the attachment holes that were already final size in order to remove the powder coating within the holes.


 
Nov 11, 2023     Finishing the Cabin Interior       Category: Fuselage
I soldered the connections between the Showplanes flap positioning device and the flap actuator, and mounted the device on the actuator. I tested it using the lawnmower for a power source. Works great.

https://youtu.be/mE7THT1__9U?si=oDk11IH7C15_Vh7i

I cleaned the seatbacks and flap actuator supports with ekockean because they got splattered with a little oil from rivet gun. Rinsed with water in the shower and hung them up in the booth at 75 degrees. Will touch up the primer tomorrow.


 
 
Oct 23, 2023     Finishing the Cabin Interior       Category: Fuselage
Drilled holes in the backrest brace for mounting the flap actuator covers and installed the platenuts. Made rectangular washers 1/16" thick to place between the halves of the center bearing. This was necessary to prevent binding of the actuator weldment. Final torqued and torque-sealed the attachment bolts for the three bearings supporting the weldment.


 
Oct 21, 2023     Finishing the Cabin Interior       Category: Fuselage
Still working on the flap actuator area. Made the spacer a bit longer than specified to make the actuator lie a bit more parallel than the plans. The motor is closer to the copilot side cover but won't come in contact with it.


 
Oct 19, 2023     Finishing the Cabin Interior       Category: Fuselage
I've been working on the electric flap actuator installation. Also primed the remaining seat back parts and a forward cabin cover.


 
Oct 11, 2023     Finishing the Cabin Interior       Category: Fuselage
I riveted the right seat back together, finished fitting up the forward center cover / heat baffle, topcoated the forward center cover / heat baffle, and topcoated both seat back braces. Now working on flap actuator and will prime and topcoat the remaining seat parts as paint booth becomes available (I like to let primed or topcoated parts cure in elevated temps in the paint booth for a couple of days so it takes a while to work a batch of parts through the painting process.)


 
Oct 10, 2023     RV9 Wing Laser Cut Parts       Category: Laser Cut
The pic shows an excerpt from Rev 5.6 of Vans LCP part list (released Sept 26, 2023, attached) detailing the timing for RV9 wing laser cut parts. Other log entries show that the wings were complete and ready to ship from Exemplar on June 2, 2022. The attached part list shows only one part that was in inventory before June 2, 2022: VA-195C "Access Hatch Doubler". Therefore, my interpretation is that the only LCP that could be installed in my wings is VA-195C. This part has been identified as "acceptable for use" by Van's and is easily inspected going forward.


 
Oct 04, 2023     Finishing the Cabin Interior - Seat backs       Category: Fuselage
Over the last week I've made the parts for the right seat back and drilled all the rivet holes. I've deburred all edges and holes and primed most of the parts for right and left seat backs. I also fit up the forward cabin cover for the fuel pump area, cleaned up the parts, and primed them.


 
Sep 16, 2023     Make custom seat brace Category: Parking Lot
I have the 040 alclad to make a longer seat brace to go with the forward seat position on pilot side. I'll wait until I have the actual seats so I can make it the correct size for me
 
Sep 14, 2023     Finishing the Cabin Interior - Seats       Category: Fuselage
Countersunk the tunnel cover for rivets. Primed (duplicolor) the tunnel cover supports and tunnel cover.

Installed platenuts around the stick boots and where the tunnel cover attaches to the fwd seat floor.

Made parts needed to build the seat backs.


 
Sep 12, 2023     Finishing the Cabin Interior - Tunnel Cover       Category: Fuselage
Finished shaping the tunnel cover supports and tunnel cover.


 
Sep 07, 2023     Finishing the Cabin Interior - Tunnel Cover       Category: Fuselage
This is the first entry in quite a while. We went to Airventure then I spent 3 weeks in Oshkosh at the Sport Pilot Academy (was terrific).

Working on the tunnel cover and tunnel cover supports.


 
Aug 08, 2023     Finishing the Cabin Interior       Category: Fuselage
We're back from Airventure! I'm in the process of making the tunnel cover supports, shown in the photo.


 
Jul 17, 2023     Finishing the Cabin Interior       Category: Fuselage
Made eight square washers for mounting the wear blocks. Not much progress lately because I've been studying for flight training in Oshkosh later in the summer.


 
Jul 15, 2023     Initial Notice       Category: Laser Cut
This is the initial email notice that my QB wings may have laser cut parts (LCP).


 
Jul 11, 2023     Finishing the Cabin Interior       Category: Fuselage
Match drilled the wear blocks to the baggage compartment bulkheads. Temporarily installed the baggage compartment bulkheads.


 
Jul 10, 2023     Finishing the Cabin Interior       Category: Fuselage
Made two wear blocks for the shoulder harness cables where they pass through the baggage compartment bulkhead.


 
Jul 09, 2023     Finishing the Cabin Interior       Category: Fuselage
Finished drilling the rest of the platenut mounting holes and installed all of the platenuts in f-706 for mounting the baggage compartment bulkheads.


 
Jul 07, 2023     Finishing the Cabin Interior       Category: Fuselage
Finished notching and drilling the holes in the upper baggage compartment bulkhead. Finished match drilling all of the baggage compartment bulkhead mounting holes to the f-706 bulkhead. Started drilling the holes for mounting the platenuts on f-706.


 


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