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Project:
tgrassman
-
All Modified Project Activities / Entries :
(Please mouse-over any icon to get a description of that function).
Categories
Show All Entries
- (133)
Research
- (2)
Workshop
- (2)
Empennage
- (7)
Fuselage
- (32)
Firewall
- (5)
Tail Feathers
- (7)
Wings
- (24)
Controls
- (7)
Avionics
- (11)
Lighting
Instrument Panel
Landing Gear
- (7)
Engine
- (18)
Propeller
- (3)
Fuel System
- (3)
Interior Finish
- (3)
Paint / Decals
Inspection
- (2)
Tools
Wing ribs
Builder Name:
Tim Grassman
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Project:
Vans - RV-14A
-
VIEW REPORTS
Total Hours:
196.5
Total Flight Time:
Total Expense:
N/A
Start/Last Date:
Sep 25, 2019 - Jul 29, 2023
Engine:
Lycoming YIO-390-EXP119
Propeller:
Hartzell Constan Speed
Panel:
Garmin G3X
Friendly URL:
https://eaabuilderslog.org?s=tgrassman
Home or Last Project Picture
Sep 27, 2019
work bench
Category: Workshop
Fabricated an 8 ft workbench with inset for back riveting
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Oct 09, 2019
Years of research
Category: Research
I have spent many hours of research on my decision to build the RV-14A. Originally I was interested in the RV8 but when the RV14 came out and I had the opportunity to sit in one in the factory, i enjoyed the extra space. Then the dilemma was tricycle gear or taildragger. Although i like the look of the taildragger I have no experience with them. Not that I couldn't learn since this process is all about that, but I simply opted for something I was more familiar with.
Oct 09, 2019
Kit Arrives
- (4 hours)
Category: Empennage
Empennage kit arrived today from Vans Aircraft. And I began unboxing. These guys really know how to pack things. many items were secured with gorilla tape. Very strong stuff. I was thinking one could just build an airplane out of that stuff. The inventory was straight forward. There are 9 sub kits plus the skins. The most time consuming part was going through the bags of hardware. It is important to verify all of the nuts and bolts because there were no extras.. In all i found a few missing items and emailed Vans. The parts are on the way. I would suggest to anyone that is unfamiliar with aviation bolts to use a 6 inch ruler with 32nd increments to measure bolt length as it helps a lot. Since the bolts are unlabeled I put each variety in its own bag for easy finding later. All small parts were placed in storage containers and shelved.
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Nov 15, 2019
Rudder
- (38 hours)
Category: Empennage
Started Rudder 10/17/19 finished 11/5/19
Th rudder is a fairly simple part but also somewhat difficult in that it has a trailing edge wedge that needs to stay as straight as possible after riveting. This was my first part that I uses the back riveting method to secure the stiffeners as well as double flush riveting.
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Spar doublers riveted with nutplates
Mock up of Rudder 7
initial fitting of skin to structure
All parts clecoed for fitting
Machine countersinking trailing edge wedge
Rivets placed in holes for backriveting
Stiiffeners riveted and 3M VHB tape setting on trailing edge
Rudder Leading edge rolled and rudder completed
back riveting tape applied ti hold the rivets in place
double flush riveting trailing edge to wedge.
back riveting stiffeners to skins
Nov 15, 2019
Horizontal Stabilizer
- (53 hours)
Category: Empennage
Started horizontal stabilizer on 10/28/19 finished on 11/15/19
My largest part to date. The finished stabilizer is over 8 feet long. Th process begins as always with prepping the raw parts by removing burrs form edges and holes. There are two spars that require quite a bit of work by adding doublers and hinge brackets. I utilized the drill press for these critical holes. Once the spars are built up ribs are added to the forward spar. The assembly is vey floppy until the skin is attached, then the assembly is solid. Th skins are prepped by dimpling all holes for flush rivets.
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rear spar doubler final drilling
Rear spar doubler riveting
parts prepped for priming
Primed parts
HS skins primed
Dimpling skins
machine countersinking spar flanges
Front spar and ribs
Finished horizontal stabilizer
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Dec 31, 2019
Elevators
Category: Empennage
Started elevators on 11/15/19 Finished 12/10/19
There are two elevators to construct. The left and right are different in that only the left side has a trim tab. Again the process of mock up and getting a handle on the overall assembly. Items are match drilled de-burred and dimpled. There is the addition of a trailing edge that also needs to be machined. Pro seal is used to secure high density foam ribs to the trim tab and trailing edge aft of the rear spars.
Elevators
Fitting elevator parts
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Machine countersinking trailing edge wedge
Match drilling trim tab to left rear spar
Skins prepped for priming. Stripes are where foam block are adhered to skins
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Elevator assembly
inside elevator prior to blind riveting ribs together
Back riveting rib to bottom left elevator skin
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Jan 16, 2020
Static system
Category: Empennage
I initially installed the static system provided with the kit and really didn't like the way the tubing attached to the static port rivet. I opted to replace this system with one from Cleavland aircraft
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Jan 30, 2020
Aft Fuselage
Category: Empennage
On to the Aft fuselage. This is going to start to look like an airplane. Lots of large parts and some new processes. Fabrication of various pieces of raw angle stock into parts is required. Bulkheads are prepped by match rilling stabilizer attach doublers and riveting together the halves. This is where design differences come into play between the tricycle gear version and the tail dragger version. Next the bottom skin is prepped and riveted to the bulkheads to create the base for the assembly. Longerons are prepped and inserted into slots on the bulkheads where the are providing support for the side skins. After the side skins are in place wiring is installed to the tail for lights and avionics. This is a great time to do some research on other things to install as access becomes more and more difficult. Optional things such as yaw damper brackets, GPS antennas, etc should be considered. Top side skins followed by the very top is riveted in place.
Aft fuselage
Matchdrilling bulkhead to Horizontal stabilizer supports
bellcrank ribs attached to bulkheads
bottom skin fitted to bulkheads
dimpling bottom skin
side skin fitted to bulkheads
Riveting side skins
wiring harness to tail
prepping for top skin riveting
vertical stabilizer fitted for match drilling attach bolts
Done for now on to wings
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skin dimpling
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aft fuselage bottom skin with longerons
Jan 30, 2020
Flaps
Category: Wings
Wing kit received and inventory complete I started the flaps on 1/24/2020 as first wing sub assembly. Just wanted to complete a few small parts bore tackling the spars. The flaps are fairly simple. I am completing the left and right side by side. There are a number of nose ribs that need to be processed with deburring and dimpling as well as ribs and spars. Flap hinges need to be straightened and fabricated with machine countersunk rivets. Flaps completed on 2/3/2020.
Flap parts
mock up of internal structure
mock up of flap for match drilling
Riveting ribs to spar
Left and right flap internal structures complete
prepping for spar riveting
Top skin installed
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Finished Flap
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Feb 27, 2020
Ailerons
Category: Wings
Started ailerons on 2/5/2020. There are a lot of parts to cut debur and process as with all the assemblies. The process is similar to flaps with a nose assembly built first the skins attached. The aileron skins utilize stiffeners instead if ribs. Stiffeners are backriveted to skins. The Trailing edges are joined like the flaps with an aluminum wedge sandwiched between them. Ailerons completed 2/22/2020.
Ailerons
Aileron leading edge
Aileron spar riveted to nose ribs
Dimpling skin
top skin with stiffeners installed fitted for riveting
Straight stiff support to trailing edge prior to riveting top skin to spar
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Trailing edge wedge
Feb 27, 2020
Main Spars 2/23/20-2/28/20
Category: Wings
Started main spars 2/23/2020. Match drilled J channels for later use as top skin stiffeners. Over 1100 holes to process with final drilling and countersinking. Over 200 nutplates to install. Also installed aileron bellcrank brackets. Main spars completed 2/28/2020.
Main Spars
Left and right main spars
J channels clamped to spar flange. This step is to match drill holes that will be mating to skin
View of nutplates installed
Used a #30 pilot countersink cutter which fit nicely into nutplate for support
Root of main spar notice the thick billets of aluminum at the root
Upper and lower flanges complete
Apr 12, 2020
Ribs 3/4/20-4/1/20
Category: Wings
Ribs started on 3/4/2020. I started this section by doing a lot of prepping of parts. I probably have 20 hours of metalworking in the ribs and thats just deburring, fluting, and hole prep. There are 14 ribs per wing but they are not all identical. It can be difficult to keep track of what is what so I labeled them according to position. It can be hard to differentiate between left and right facing ribs. To help with this there is a small flange on the bottom of each rib that slides into lower flange of the rear spar. the inboard most rib is different from all the rest as it is thicker to support the torque tube assembly. Rib number 3 and 8 have extra work involved in attaching the flap hinges. There are bolts that are part of the main spar assembly that must be removed for final drilling the ribs to the spar with a #30 bit. the bolt holes are match drilled to the ribs with a #12 bit. Remove deburr and prime. Final assembly bolts reinstalled and torqued #30 holes riveted. I moved on with the rear spar right away. Then repeated the process for the right wing. All ribs and rear spars completed on 4/1/2020.
Wing ribs
Inboard rib with torque tube support clecoed
With spar bolts removed. I final drilled #30 rivet holes and match drilled #12 bolt holes
ribs primed and ready for installation
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riveted rib, manufactured head placed on inside thinner material
Shop heads of #30 rib rivets
Rib riveting setup, 3x gun with 10 inch set ground flat on one side for tight areas and tungsten bar
Apr 12, 2020
Rear Spar 3/21/20-4/1/20
Category: Wings
I started the rear spars on 3/21/2020. The rear spars are fairly simple. Three doubler plates need to be match drilled to the spar. They provide extra strength to the aileron hinge brackets and help support the area adjacent to the outboard flap hinge which is riveted to a rib. The inboard aileron hinge bracket is replaced by a service bulletin and beefed up due to potential cracking in the doubler plate. A large hole in one doubler must be created to match the hole in the rear spar. The hole is for the aileron linkage. The top flange receives #40 machine countersinks for dimpled skin at locations of doubler plates. The remaining holes top and bottom receive dimples. There are two additional doublers at the wing root. they are 1/8 thick aluminum and provide the rear attach point to the fuselage. They must be final drilled to the spar. There are about 10 spots that require machine countersinking for flush rivets and dimpled aluminum. I riveted the rear spar to ribs with a pneumatic squeezer. Left and right rear spars completed on 4/1/2020.
Rear Spar
Inboard aileron hinge
Matching hole from spar to doubler. First used a step drill then a dremel with metal cutting bit.
Rear spar attached for final drilling of rib rear flanges
Rear spar primed and dimpled prepping for rivets
Rear spar doubler plates. Large hole final drilled to 11/32 then reamed to 3/8
Apr 12, 2020
Top Skins 4/1/20 -4/11/20
Category: Wings
Internal structures for left and right wings completed on 4/1/2020, on to top skins. There are 4 pieces for each wing and a ton of rivets. Lots of holes to prep for countersink rivets. The skin above the inboard 4 ribs require machine countersinking due to doubler plates that provide extra thickness to the wing walk area. These are drilled with a #40 countersink cutter in a microstop. The rest of the holes receive dimples. The outboard skin thickness is .025 and overlaps the inboard skin which is .032 thickness. Where the two skins overlap at the main spar, the combined thickness must be tapered to match the fuel tank skin thickness of .032. I did some back riveting when I had a helper and some traditional when solo. Riveting is from center of of each skin outwards leaving the joint last. This is supposed to provide tight skins. The J channels that were match drilled during the main spar section are dimpled and primed and slid into place from the sides. the short j channel sits under the long which is against the skin. Lastly the outboard aileron hinge bracket is installed and some #19 holes that were drilled for nutplates at the wing root need to be countersunk. Right wing Top skins completed 4/11/2020.
Top Skins
Top skins fitted
Machine countersinking #40 wing walk area. #19b holes drilled at left edge (wing root) for #8 screws
Dimpling skins for #40 rivets
Taper of skins at leading edge
Upper ribs dimpled prior to skin attachment
Right wing completed
Right wing skin riveted
Short j channel on left overlaps skin seam on to long j channel
Countersink for #8 screw dimpled skin at wing root for wing root fairing
Outboard aileron hinge riveted to rear spar and outboard rib
Apr 27, 2020
Outboard Leading Edges
Category: Wings
With the left and right aft wing sections complete with exception of the bottom skins, I move on to the outboard leading edges. They are a fairly simple part, but it is important to make sure the nose edges don't cause creases in the skins. After the assembly is complete it is riveted to the corresponding main spar.
Outboard Leading Edge
7 ribs for each outboard leading edge
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rib before fluting is not flat
flutng the rib to strsighten it out from the manufacturing
rib after fluting
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May 30, 2020
Wing systems routing
- (4 hours)
Category: Wings
Installed wing wiring harnesses
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Jul 04, 2020
Fuel tank pressure test
- (3 hours)
Category: Wings
Tested both fuel tanks after sealant has cured for about a week. I used a bike pump to put a bit of air into the tanks throght the provided test kit fitting. The balloon is connected to the fuel strainer to provide pressure relief. Once air is in tank is squirted with soapy water and bubbled should form at any leaks. My right tank had a leak at the fuel cap and tank vent union. After swapping caps and adding sealant to the union both tanks hold pressure and seam to be leak free.
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Jul 06, 2020
Right Bottom skin dimpling and right wing tank installation
- (6 hours)
Category: Wings
Started the morning creating a lap joint for bottom skins and dimpling the right wing bottom skin panels to finish them. Note that if flap attach point bushings were installed, they will probably have to be removed to get the bottom skins to fit over them. The overlap of the outboard skin on to the inboard skin is tapered to create a thickness of .032 to match the fuel tank skin. Next project for the day was installing the right wing tank. Tank skins fit very tight and require a bit of edge filing. There was a bit of on and off for this. I had the wing flat on the worktable for the fitting. There was a lot of rotating the wing to access the top and bottom.
Creating tapered lap joint
dimpling bottom skins
Fitting dimpled skins
Aligning right tank
Tank after install
tank to outboard leading edge
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Jul 07, 2020
Left wing tank installation
- (4 hours)
Category: Wings
Same as right wing tank installation. Note the protrusion on the leading edge is a piece of PVC to protect the stall vane from damage as well as to protect the builder from damage as it is a bit if a hazard.
left wing tank
Jul 08, 2020
Landing light lens
Category: Wings
Fabricated left wing landing light lens. I used a dremel with a cutoff wheel and plexiglass bits to drill the holes.
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Jul 09, 2020
Tank skin gaps
Category: Wings
After much research and emails to tech counselors and with a reputable paint shop I have decided to file a larger gap between my tank and adjacent skins. The current zero gap that I have could case paint to crack with wing flexing and does not facilitate potential removal of the tank for maintenance. Also having some issue with pillowing at the tank to leading edge butt joint.. More work to be done here.
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Jul 13, 2020
Aileron actuation
- (5 hours)
Category: Wings
Started work on the aileron actuation system today. Process starts by cutting two pushrod tubes to specified length followed by fitting ends for the tubes to hold rod end bearings.
Next is the bell rank to aileron pushrod. A smaller steel powder coated tube fabricated with threaded rod ends and end bearings.
Two bellcranks have some minor drilling and nut plates. Installation requires bushings.
Ailerin actuation
How to draw a straight line on tubing
Adjusting rod ends for fitting
Drilling aileron torque tubes for rod ends
Adjusting threaded rod end
Threaded rod ends that go into Aileron torque tubes
Pipe cutter for precise cuts
Aileron bellcrank
Aileron pushrod drilling
Match drilling Torque tube to rod end
Jul 17, 2020
Left wing tip install
- (5 hours)
Category: Wings
Started on the left wing tip fiberglass install. This required me to cut the flanges down to 1/2 inch. The aileron is secured with a jig to the neutral position.The tip is placed on the wing and a ratchet strap is used to apply pressure so the leading edge has no gap. Holes are match drilled #40.
Tip as it comes from the factory
Aileron secured with jig
Tip secured with strap to close gap at leading edge
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Jul 19, 2020
Pitot mast installation
- (5 hours)
Category: Wings
Garmin GAP 26 pitot and Gretz mast arrived yesterday. No better time than the present to install the mast. The kit required some deeper joggling on the mounting plate in order to get flush with the spar. Also a bracket needed to be fabricated to attach it to a rib. The process was fairly seamless and the results are good.
Gretz mast kit being fitted
Provided drilling template
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Bracket not provided with the kit must be fabricated.
transferred mast profile to skin and cut out with drill and dremel
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Skin match drilled from with attach bracket from backside
after match drilling
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Jul 20, 2020
Trimmed right wingtip
- (2 hours)
Category: Wings
Trimmed right wingtip flange for fitting to right wing
Cutline
Jul 21, 2020
Left wing tip lens cover
- (6 hours)
Category: Wings
Cut and fitted the left wing tip lens cover. Super tedious process of on off sand and repeat to get this fitted properly. The tip needs to be prepped by making sure the inset area is squared up. The lenses come connected and you cut it in half to get the left and right sides. Then proceed to fitting. I used snips to get first cut then sanded with a small belt sander and by ultimately by hand to get final fit. I established a reference at the forward tip and the rear peak and worked towards the corners to fit each side individually.
Right shows the starting point left shows the final fit
Jul 22, 2020
Right wingtip lens cover
- (4 hours)
Category: Wings
Finished right wingtip lens cover
Starting with the unprocessed right half
initial cutline
tape line for fine tuning
Small belt sander for larger material removal and used 150 grit paper on small bucking bar for small
Final product
Jul 23, 2020
Rudder bottom fairing
- (5 hours)
Category: Tail Feathers
Started the rudder bottom fairing. This requires drilling a few holes and cutting on the provided scribed line followed by precise sanding to get edges to sit flush with the rudder skin. After alignment is complete, a hole pattern is laid out for drilling left and right attach points for nutplates. Starting with #40 then #27 to accommodate #6 screw. Nutplates are then match drilled to the rudder and metal deburred. Nutplates get riveted and rudder fairing gets its holes machine countersunk.
cut and sand to scribe lines
sanding setup for flat surface
making minor adjustmets
secured for drilling #40
Drill forward to aft and cleco
Holes drilled next step upsize to #27
Match drilling nutplates
Dimpling nutplates with reduced diameter male and female dies
Dimpling nutplate holes for 426-3 rivets. Forward most nutplate requires machine countersinks.
skin too thick for pop rivet dimple. Was forced to use tight space dimple tool here.
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Utilized tight space yoke on pneumatic squeezer.
finished product
Jul 24, 2020
Rudder top fairing
- (3.5 hours)
Category: Tail Feathers
Installed rudder top fairing. Cut flange to 1/2 inch, match drilled holes, dimpled with 120 degree die for CS4-4 rivets. I will use thin washers next time as a backer for pulling future rivets int fiberglass for better long term security.
Rudder top fairing
Squaring up recessed area
Installing rivets
Top Fairing installed
Jul 26, 2020
Elevator attachment
- (03 hours)
Category: Tail Feathers
Started the elevator attachment section by installing rod end bearings. I fabricated a wrench out of pvc pipe for installation. The measurements are very precise and it is difficult to measure accurately with a small ruler. My first attempt caused rubbing at the outboard HS rivet line on to the rolled leading edge. After researching the specs on the rod end bearing i was able to get a good measurement to the top of the rod from the skin so i could use my depth gauge on my digital calipers. After reinstallation the rubbing is gone. All gaps are 1/8. The on off of the elevator can be challenging. I made a homemade version of Avery temporary assembly pins out of pegboard hooks.
Rod end tool
Available at ACS
Measuring rod end distance
temporary left elevator install
Temporary left and right install
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Jul 27, 2020
Home made assembly pins
Category: Tail Feathers
For about $5 you can make these assembly pins that work like the ones from Aircraft Spruce that cost $20 plus shipping.
Parts:
3/16 rod (Lowes) Hillman 3/16-in dia x 3-ft L Zinc-Plated Steel Solid Round Rod Item #26256Model #11150 $2.98
https://www.lowes.com/pd/Hillman-3-16-in-dia-x-3-ft-L-Zinc-Plated-Steel-Solid-Round-Rod/3055089
3/16 turnbuckle (Lowes_ National Hardware N100-394 (2172BC) 3/16-in x 5-1/2-in Hook/Eye Turnbuckle in Zinc Plated $1.71
https://www.lowes.com/pd/National-Hardware-N100-394-2172BC-3-16-in-x-5-1-2-in-Hook-Eye-Turnbuckle-in-Zinc-Plated/1002716428
Tools required Tap/Die set
Place about 3/4 inch of rod in vise and bend beyond 90�r>cut off bent end and cut threads with a 12-24 die
remove hook from the turnbuckle and retap with 12-24 so the threads match
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retap with 12-24
Cut 12-24 threads
insert pin into turnbuckle
slide into bearing
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Remove turnbuckle
Jul 28, 2020
fuselage kit arrival and inventory
- (6 hours)
Category: Fuselage
Fuselage kit arrived. Parts inventoried
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Jul 30, 2020
FWD and MID Fuselage bulkheads
- (4 hours)
Category: Fuselage
Fuselage kit arrived and jumped right into the build. This requires machine countersinking again as was done with the main wing spars. Thankfully not nearly the amount of holes. Make sure to back up the pilot with a piece of thicker material when countersinking. Since I am waiting on a .311 reamer to arrive I am jumping around this section a bit. There are a lot of small tasks to do anyway.
Section 25
Parts for this section
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center spars require machine countersinks for rivets and nutplates
Aug 01, 2020
Section 25 fwd and mid fuse bulkheads
- (8 hours)
Category: Fuselage
More work on FWD and MID fuselage structures. Waiting on a .311 reamer for finishing touches.
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Aug 18, 2020
Seat ribs and mid fuselage lower structure
Category: Fuselage
.311 reamer finally arrived after many delays. So now I was able to attach the seat ribs to the rear spar and rear bulkhead. The gear brace was back riveted to the bottom skin and then the seat rib assembly to the bottom skin.
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Seat rib attachment to aft center spar
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prepping for back riveting
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Aug 25, 2020
Baggage ribs
Category: Fuselage
Riveted baggage ribs to rear bulkhead and to bottom skin.
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Aug 30, 2020
Section 26 completion
Category: Fuselage
Finished riveting baggage ribs to skin
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Sep 02, 2020
Firewall
Category: Fuselage
The firewall is made if stainless steel. It is a bit more difficult to work with in that it is harder to drill. Luckily there were only a couple places to make holes. There are four pieces that are assembled with doublers, plus a tunnel structure which provides an area for a cooling flap assembly.
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Sep 03, 2020
Firewall completion
Category: Fuselage
Finished all firewall riveting.
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Sep 11, 2020
Forward Fuselage lower structure
Category: Fuselage
In this section forward belly skin are prepped and riveted to the muffler shroud ramp and firewall. Tank sealant is used to seal exhaust gasses from entering cabin. Parts made in previous sections are joined. Battery box and cabin heat vents are mounted to firewall.
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Sep 27, 2020
Joining FWD and AFT sections
Category: Fuselage
Section 29 brings all the fuselage subassemblies together to create the Mid fuselage section.
Section 29
Forward and aft sections clecoed together for match drilling of the side plates
Upper drag fitting temporarily attached for match drilling
Fuselage section oriented on its side for bottom skin riveting
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Oct 09, 2020
fuselage side skins and siffeners
Category: Fuselage
Side skins are positioned on fuselage structure for match drilling of cowling hinges, side plates and upper drag fittings. Machine countersinking of sideplates and longerons at all locations where they come into contact with dimples skins. Skins are dimpled with some exceptions at the wing root area.
Side skin positioned on fuselage
Match drilling skin to firewall to cowling hinges
Maching countersinking side plates after match drilling to upper drag fittings
both side skins positioned for match drilling
Dimpling wing skin, taped areas are hidden and do not get dimples
side stiffeners clecoed in place
Oct 18, 2020
Jd Air latch
Category: Fuselage
I decided to do a small modification and install a JDAir latch. This took a couple days to complete. There is no template for the RV14 so you need to make your own. There are two rows of rivets in the skin for the stock Vans latch. I kept the upper row and cut a hole for the latch which removed all but 2 rivets from the lower row. One rivet hole remains in the skin between the two pieces of the latch. I later filled it with a rivet and machined out a spot in the latch so the shop head would not make contact. Some people use Bondo here to fill the hole.
Fabricated brackets from .063 angle
Aligned top bracket to existing holes
Cut out lower rivet holes for latch assembly
Match drilled lower bracket to skin
dimpled holes
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Nov 09, 2020
October Fuselage work
Category: Fuselage
Things have slowed down a bit with other commitments, I am helping with the Porter High School Tango Flight RV12is build but work continued through October on the fuselage. I have spent a lot of time researching the electrical side of the project and decided to purchase a prebuilt harness from SteinAir. Unfortunately it was not include with the kit from Vans. It will be plug and play into the existing wing and tail harnesses that Vans provides. I have decided to go with the IO-390EXP119 engine option and the finishing kit has been ordered for that option.
Back to the fuselage work. Since early October I have mostly completed section 29 All skins and stiffeners are installed.
Mostly completed mid Fuselage
Fuselage wiring harness
Nov 22, 2020
Mating season
Category: Fuselage
Time to mate the tail to the fuselage. This was a lot easier than I thought it would be. Everything fit perfectly. A testament to the quality of the kit. Originally I had the fuselage up on a table to put the tail on but didn't like the height so I built a 4 foot by 4 foot fuselage stand in wheels. It worked very well to slide the fuselage up to the tail. Everything is clecoed in place so I can recruit my son to help with some riveting.
Set up for mating this proved to be a bit high
built a 2 foot stand for better working height and mobility
tail clecoed to mid fuselage
put the tail feathers on just to see how it looks
Dec 06, 2020
Fuselage mating complete
Category: Fuselage
The fuselage has been successfully riveted together. Some of this was challenging since there are tight places to fit a bucking bar.
Bottom skin lap joint
side skin lap joint
Top skin to bulkheads and shoulder harness luggs
Baggage bulkhead
baggage rib to bulkhead
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Dec 08, 2020
Fabricated fuel lines
Category: Fuel System
A total of four fuel lines need to be fabricated or purchased from a vendor. I chose to fabricate mine since I had the tools and materials. I had a couple that I didn't feel fit quite right so had to order another coil of tubing. They don't give you any to practice on so there is a bit of learning curve on these bends. After I finished i discovered I could do a better job next time by running the tubing through a piece of 2X4 with a 3/8 hole drilled through it. This does a better job getting the little kinks out than by hand. Make sure to clean the tubing well in case any wood breaks off and gets inside.
Right fuel line secured
center tunnel left/right fuel lines to valve
left fuel line
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flaring tool, bender, cutter
flared tube
drilled 2X4 for straightening tubing
Dec 21, 2020
Baggage compartment
Category: Fuselage
Installed baggage floors, side walls and flap motor bracket.
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Dec 27, 2020
Roll over structure
Category: Fuselage
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Dec 31, 2020
Section 33 Upper Forward Fuselage
Category: Fuselage
Jumping ahead while waiting to do some interior painting. I started the upper forward fuselage. Mostly the normal parts prep and assembly. There is a good bit of machine countersinking and install of many types of nut plates. Be sure to pay close attention to that. Also you are required to fabricate some rods for the canopy release. you need to drill two holes on each rod oriented on the same line. I found a video on hint for homebuilders regarding drawing a straight line on tubing that has been helpful you can check it out here.
https://www.eaa.org/videos/4605094533001
In this case the tubing is small so I used a combination square as a straight edge by placing the tubing in between the ruler and the sliding handle. There are 4 canopy decks that are .040 thickness that require dimpling. in coordination with this the underlying longeron needs countersinking. These are for CS4-4 rivets. I was not fond of this process as I felt the countersinks seem to be very deep to fit the dimples .040 canopy deck. I think machine countersinking vs dimpling might work here but you would need a 120 degree countersink bit.
Section 33 Upper FWD Fuselage
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Jan 30, 2021
Flap motor
Category: Controls
When doing section 34 flap motor installation make sure to also do section 54 flap position sensor. This will save a lot of taking things back a part later. A hole needs to be drilled in the crank for the sensor rod prior to installation. The flap torque arms are match drilled with the flap crank arm. This is done with the jig included in the wing kit. Match drill #30 and final drill #12 for an3 bolt. Grease and slide arms in to bearing blocks from sides and into crank arm. Attach motor to the top. Run to full extension per section 54 to set flap position sensor and tighten down sensor.
Flap Actuation
#30 hole for sensor rod
match drilling with jig
Actuator installed
flap position sensor
Feb 01, 2021
Rudder and brakes
Category: Controls
After prepping brake pedal parts I had them anodized for better wear resistance. I found that the rudder cross tubes were bowed from the factory and needed some adjustments to reduce friction on the center bearing block. Apparently this is common from welding. Brake pedals and master cylinders were installed. Crosstubes deburred and greased. They are fitted into bearing blocks on each end and bolted to sides. There are three positions to choose from for rudder pedal attachment. A center support bearing block is attached. Plans detail lengths for brake lines. The fitting is very good and compression fittings go together easily. Rudder cables are routed through bushings under baggage floors through spars and tunnel to rudder pedals. The most difficult part was installing cushion clamps to hold the plastic sleeve to the side of the tunnel. Access is limited with fuel system installed.
Rudder & Brakes
pedal installation
brake master cylinder install
bent crosstubes
fitting rudder assembly
reservoir to master cylinder lines
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brake reservoir
Feb 01, 2021
Aileron and elevator controls
Category: Controls
Aileron and elevator Systems
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Feb 23, 2021
Finish kit arrival
Category: Fuselage
Finish kit arrived. Many back ordered parts.
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Mar 08, 2021
Rear window
Category: Controls
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Rear window will be trimmed back to match shim
Apr 01, 2021
Canopy frame
Category: Fuselage
Flattest surface I have is the kitchen counter top so this is where I aligned the frame
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Apr 13, 2021
Forward fuselage to skin
Category: Fuselage
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Apr 14, 2021
Canopy
Category: Fuselage
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Apr 15, 2021
Aileron trim servo
- (4 hours)
Category: Controls
Installed aileron trim servo to right inboard wing access panel.
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Apr 17, 2021
GAP 26 Tubing
Category: Avionics
Routed Tubing for Garmin GAP 26 pitot
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Apr 19, 2021
GMU 22
Category: Avionics
Fabricated GMU 22 magnetometer mount for left wing
Apr 25, 2021
Canopy drilling
Category: Fuselage
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May 26, 2021
Canopy Fairing
Category: Fuselage
The canopy faring has taken a long time. Started by filling the void where plexiglas meets the aluminum with an epoxy microballoon mixture. Followed by sanding. Then applying resin soaked fiberglass in layers to build up the proper shape. After curing it is sanded and filled many times to get the proper shape.
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Jun 11, 2021
wing wiring
Category: Wings
Secured wing wiring harness in preparation for bottom skin installation.
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Jun 11, 2021
Tires
Category: Landing Gear
Built up tire assemblies and fabricated and installed gear angle braces.
Grove main wheels and Matco nose wheel
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Jul 05, 2021
Wing bottom skins
Category: Wings
7/5-7/15 Riveted wing bottom skins.
long rivet set purchased for these rivets
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tight spaces for riveting
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Jul 19, 2021
Battery and starter contactors
Category: Firewall
Installed battery and starter relays to firewall
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Jul 20, 2021
Main Gear
Category: Landing Gear
Installed the main landing gear legs. Slight modifications were required to get the gear legs to slide into the slot. The bolts are close tolerance and quite difficult to install. This required a bit if time in the freezer to slightly shrink them.
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Aug 01, 2021
OP 56 Tail Light
Category: Tail Feathers
Installed AEROLED tail light to bottom rudder fairing
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Aug 08, 2021
Avionics finalized
Category: Avionics
I have finalized my design with Steinair for my avionics. It will be a dual screen Garmin G3x touch system with a GNX 375.
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Aug 15, 2021
Engine sensor block and firewall grounding block
Category: Firewall
Installed firewall sensor block which will be used in conjunction with Garmin engine sensors as well as an electrical grounding block .
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Aug 19, 2021
Voltage regulator
Category: Avionics
Fabricated a hinged panel for B&C LR3D voltage regulator.
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Aug 24, 2021
Cowl Flap modification
Category: Firewall
Since I have chosen the IO-390 EXP199 engine i have modified the fuselage to accept the cowl flap assembly. Originally the exhaust from each cylinder would have connected into one pipe and run down the center tunnel. The new setup requires no tunnel so it is modified into a cowl flap for engine cooling.
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Aug 28, 2021
Wing tips
- (8 hours)
Category: Wings
Returned back to wings for tip fitting and installation. Fiberglass tips are large. They require match drilling to wing skins, countersinking, trimming, and nut plate installation.
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Oct 10, 2021
Empenage Fairings
Category: Tail Feathers
10/10/21- 11/1/21 Attached Tail feathers for fairing work. This was my first time attaching all the tail. It went together very well. Three fiberglass layups are required to finish the vertical and horizontal stab fairings. I used 2 layers of 8oz. cloth. After they cure they are trimmed and adhered to the fairings with an epoxy/flox mixture then glassed in. The empenage fairing was a lot more work. All the holes had to be blind drilled since the fairings are opaque. This requires the use of magnets to locate the holes. Many hours were spent fitting this part.
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Oct 11, 2021
Engine mount
Category: Engine
Installed engine mount
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Oct 29, 2021
Main gear axles
Category: Landing Gear
Installed main gear axles and measured for toe in /out. Found that the left and right each required a shim.
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Nov 04, 2021
Nose gear installation
Category: Landing Gear
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Nov 07, 2021
Brakes
Category: Landing Gear
Installed brakes
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Nov 08, 2021
Brake lines
- (1 hour)
Category: Landing Gear
Fabricated brake lines out of 1/4 inch tubing.
Tubing Cut and flared
tubing installed
Nov 18, 2021
Avionics arrived and inventory and install
Category: Avionics
Installation of avionics took a good bit of time. Mostly locating the exact placement of all of the Garmin equipment behind the instrument panel. I was able to place most of the items where they are accessible.
Stein Air Shipping crate
Rear view of Stein panel
Panel installed
Top View of equipment
Radio center stack wiring and CO2 sensor
GAD29, GEA24, backup battery
Firewall grounds
Power bus and avionics relay
GAD 27 and Comm Radio
Avionics to fuselage harness interconnect
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Jan 03, 2022
antennas
Category: Avionics
Installed antenna in preparation for initial power up of panel. Transponder, Comm and GPS antennas and RG400 cable installed.
GA35 antenna
Antenna doubler
transponder antenna doubler
Ga35 coax routing
Transponder antenna
Jan 04, 2022
Classic Aero interior
Category: Interior Finish
My Interior arrived. It took about nine months from the time I ordered it. Everything was fitted temporarily to look for any issues. A small modification is required to fit the upholstery with the JD Air Latch.
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Jan 17, 2022
First power up
Category: Avionics
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Mar 01, 2022
Wheel fairings
Category: Landing Gear
March and April 2022. While waiting for the engine to arrive I decided to get started on the wheel fairings. Main wheel fairings are fitted to the gear leg by cutting out a slot and creating clearance for the brake lines. The mounting brackets are fitted by creating an epoxy built up area to provide support. When finished much work was requires to get a good alignment with front and rear halves. The gear leg fairings and cuffs were also prepared.
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Jul 07, 2022
Engine prep
Category: Firewall
Engine arrived in late June. I began to prep the engine with proper oil fittings, prop governor, and removal of the gauge port from the fuel system SERVICE BULLETIN 18-05-21. I also installed a BC-410H standby alternator.
prop governor mounting pad
Prop governor installed
removed this gauge port
installed pipe plug
oil fitting installation
BC410-H Alternator installed on vacuum pad
Jul 11, 2022
Engine installation
Category: Engine
Installed engine to mounts. Not an extremely difficult task but there is definitely some frustration getting all the holes to align. Removed crankshaft plug to accommodate the constant speed prop.
Upper engine mount
crankshaft plug was removed
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aligning engine to mounts.
Jul 11, 2022
Hanging prop
Category: Propeller
After engine was hung we moved on to the Prop. the backplate was prepared to get mounted to the hub.
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Jul 12, 2022
spinner fitting
Category: Propeller
Started in fitting of the spinner, Cutouts for prop blades, and fitting to bulkheads.
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Jul 18, 2022
Standby voltage regulator install.
Category: Avionics
I needed to mount a standby voltage regulator for my standby alternator. I decided to put it back to back with my primary on a hinged door for some accessibility.
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SB1B-14 standby regulator
LR3D -14 regulator
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Aug 05, 2022
Cowling
Category: Engine
Started prepping the cowling. Mated the halves. trimmed to scribe lines. i used a very ling 2x4 with a 4 inch sanding belt cut and attached for a long flat sander. the goal was to the the sides of the top cowl as straight as possible. Cutouts are then made on the bottom about 4 inches back from the front. this allows the fronts to mate. The mating area at the front sides is sanded so there is a butt joint fit.
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not a great fit here. this will need work
sanding for a good butt joint
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butt joint fit
initial trim of aft edge
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sanding aft edge
sanding tools
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Aug 06, 2022
Cowling
Category: Engine
Continued work on upper cowling. established the front tight against spinner bulkhead the drew a 1/8 inch line for trimming rear. The goal is to establish a 3/36 gap form cowling to spinner bulkhead
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Aug 20, 2022
Cowling
Category: Engine
Transferred rivet positions from forward skin for drilling upper cowling. Then match drilling to hinges.
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Aug 23, 2022
Spinner
Category: Engine
Drilled spinner to front and backplates. Installed nutplates.
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Aug 25, 2022
Removed rudder pedals for engraving
Category: Controls
I have a friend with a new toy, a laser engraver, so I decided to remove my anodized rudder pedals and have my registration number engraved. This was a bit of a tough job but I still have access with forward skin not installed.
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Aug 30, 2022
Lower cowling
Category: Engine
Moving on to lower cowling. I was able to borrow a hub without blades to aid in the lower cowling fitting. Two halves are clecoed together at the front and then lower cowling rear edge is trimmed to fit the forward skin. Rivet holes are transferred and drilled, then match drilled to hinges. Bottom cowling is mated to the upper, and trimmed.
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Sep 08, 2022
Cowling work
Category: Engine
Work continues on fitting the cowling. I trimmed the lower cowling to mated to the upper, and sanded the butt joint for a nice fit. I found it a good method to slip a piece of sandpaper between the two halves. While using the upper edge as a guide the lower edge is sanded.
Hinges installed and drilled.
Holes get counter sinks then riveted.
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Mismanufactured bottom cowling. The honeycomb stiffener is to far aft. I had to remove some for hing
Sep 08, 2022
Aero sport hinge pin covers
Category: Engine
Modified cowling for hinge pin covers
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Nov 13, 2022
Avionics Access panels
Category: Fuselage
Finally decided to install the avionics access panels. I really wasn't interested in doing this mod, but after laying under the instrument panel trying to do some work I realized that This would be helpful. The Kit is OP-43 from Vans. It includes two panels for use on all RV side by side models. It's a simple mod but takes a lot of time to get a nice fit. This would be a nice job for some pneumatic nibblers, but I had to settle for using the tools i have. The flanges were sealed with tank sealant.
initial layout
Drilled perimeter
cut between holes
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sanded to line
final sanding to create a paint gap
flange installation
final fit
Trimmed flanges for rib clearance
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Dec 11, 2022
Installation of GMU22
Category: Avionics
I installed the GMU22 magnetometer into the bracket and then slid it into the left wing mounting position. The connector from the airframe wiring was then installed.
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Jan 10, 2023
Oil Access Door
Category: Engine
Fabricated a new oil door on a water jet. I used 2 hartwell latches and avery hinge.
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Mar 07, 2023
Elevator travel
Category: Controls
Temporarily installed elevator to set the travel limits. This required some modification of the pitch stops to achieve the appropriate travel of 25 degrees +0-.5 down and 30 degrees +0 -.5
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Apr 02, 2023
Cowling matching
Category: Fuselage
I had some mismatch between upper and lower cowlings that required some finishing.
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Apr 16, 2023
Moving day
Category: Workshop
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Apr 19, 2023
Installed horizontal stabilizer
Category: Tail Feathers
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Apr 23, 2023
Wing installation
- (2 hours)
Category: Wings
Wings were installed by lining up holes and inserting pins then 4 large bolts were installed followed by 4 smaller . The process was fairly seamless and alignment was easily achieved.
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May 01, 2023
Cowling
Category: Engine
Added material to the cowling inlets to raise them so forward baffle seals fit properly.
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May 03, 2023
Landing lights and nav lights
Category: Fuselage
Wired and installed landing and nav/strobe lights
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May 06, 2023
Pitot Static
Category: Fuselage
Ran tubing to GSU25 and G5.
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May 26, 2023
Transition Training
- (5 hours)
Category: Research
Headed up to PA to get transition training with east coast rep Jo Czacharowski. Lots of fun over 2 days with great weather.
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May 30, 2023
exhaust
Category: Engine
Installed exhaust and EGT probes, secured wires.
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May 31, 2023
Installed Prop
Category: Propeller
With cowling work complete the prop is installed. Since this is a constant speed prop it need engine oil to actuate the blade changes. In order for oil to get out to the prop the crankshaft plug was removed. This allows the prop governor to feed oil to and from the prop hub to change blade angle and maintain RPM. A special wrench adapter is used to torque the propeller bolts.
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crankshaft plug must be removed for constant speed props
Jun 07, 2023
Fuel system calibration
- (3 hours)
Category: Fuel System
Calibrated left and right fuel quantity by adding fuel in 2 gallon increments and creating data points in the Garmin G3x configuration.
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Jun 07, 2023
Pmag timing
Category: Engine
Pmags are set from the factory for 25 degrees before to dead center. My engine requires 20. The process to change this is simple and takes just a couple minutes. By aligning the TC mark on the back of the flywheel with the engine case seam, then rotating 5 degrees in normal rotation. Then blow air into manifold pressure tubes the Pmags are reset indicated by a red flashing led turning green.
Jun 07, 2023
Drained preservation oill
Category: Engine
Drained the engine of its preservation oil, filled oil cooler and engine with 7 qts of mineral oil.
Jun 08, 2023
Weight and balance
Category: Fuselage
Aircraft was leveled and weighed
aircraft leveled
Jun 08, 2023
Oil pressure build up
Category: Engine
Removed lower spark plugs and rotated engine with starter to build up oil pressure
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Jun 09, 2023
Fuel flow testing
Category: Fuel System
Fuel flow was tested with aircraft level flight pitch attitude, as well as takeoff pitch attitude. The servo inlet line was disconnected and pump turned on. Fuel was collected over a one minute period. All fuel flows were around 45gph. Pump fed systems are required to have 125% of takeoff consumption.
nose raised to increase pitch attitude
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Jun 11, 2023
Weight & Balance
Category: Engine
Performed weight and balance calculations by leveling the aircraft, measuring the distance between the datum and the nose gear, and the datum and the main gear on each left and right side.
Multiplied the arms by each gear, wait to get the moment at all three points.
Divided the total moment by the total weight to achieve the calculation of empty weight CG
After empty weight CG is figured out then calculations are performed for maximum force, CG, and maximum aft CG as well as flight test parameters.
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Jun 13, 2023
First engine run
Category: Engine
Completed first engine run. Taxi testing and break-in of the brakes. Tested engine up to 2100 rpm.pmag tests, alternator testing.
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Jun 19, 2023
Firewall close out
Category: Firewall
As the build is basically finished I have plugged the firewall passthroughs.
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Jun 19, 2023
vinyl experiment
Category: Interior Finish
I noticed a lot of RV's that show extensive wear on the canopy rail including my own. I decided to experiment with some vinyl in this area
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Jun 22, 2023
Pitot static and transponder check
Category: Avionics
Enlisted the help of an avionics shop to conduct pitot/static system leak test, and calibration ofG3X and G5 altimetry.
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Jul 29, 2023
Airworthiness Inspection
Category: Inspection
Today I had the airworthiness inspection completed. N5875G has been deemed fit to fly.
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Aug 11, 2023
Installed interior and flight ready
Category: Interior Finish
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Aug 16, 2023
First flight
Category: Inspection
Performed first flight of N5875G. Clear morning with mostly calm winds. Climbed to 3500 ft above the field and orbited while performing engine break in.
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