So far I have built two of the Van's practice kit tool boxes and one of the practice kit airfoil sections. Each time I have improved my building skills. One thing that people really don't tell you is that it will take some time and practice to figure out the best air pressure settings, drill speeds, hand holds, positions, etc on just how to approach certain aspects of working with the aluminum sheet metal.
I purposely went through the first practice tool box without putting much thought into how to do certain things. I wanted that one to be a learning experience and that's exactly what it was. The second tool box came out much better and I was ready to tackle the airfoil section.
The airfoil kit is a bit more difficult and involved than the tool box. If you're only going to do one practice kit, make it the airfoil section as it involves far more building techniques than does the toolbox.
One thing I learned working on the airfoil is that I still didn't have all the tools I needed. Dimpling the last set of holes in a wing rib where there is basically no room to get a dimpler or squeezer in there requires a different technique. So out came the credit card and yet more money in tools was spent. You can never have enough tools apparently.
Ironically the most difficult part of the practice airfoil was bending the leading edges to a nice curved shape and working with the trailing edge wedge. Both of these required techniques that I had not ever attempted in the EAA Sheet Metal workshop, the Sheet Metal class at AirVenture or the previous practice kits.
Overall it came out ok but I again made some mistakes that I will correct on the second version of the airfoil project. The good news is that I now feel ready to tackle the empennage pieces having practiced and learned most of the techniques that will be required.
The second airfoil project is going to include everything including priming. To that end I have finally decided to use the SEM line of primer products for ease of use and simplicity. I personally think builders way overthink the priming of their parts. Having met with one of the country's top RV builders who has the Gold, Silver and Bronze Lindy trophies to prove it, he literally uses a rattlecan primer from WalMart for the professional builds that he now does for clients. Keep it simple Stupid principal in full effect here.
To that end I will now need to construct a paint booth in the shop. PVC and plastic sheeting should do the trick.
What I'm also learning is that you have to do certain steps of the build out of order if you intend to prime your parts. Most builders seem to match drill everything and cleco it together, dimple, prime and then rivet. Although I think I picked up a good tip the other night where one builder says he actually scuffs his parts before he dimples them which actually makes a lot of sense.
So hopefully the next entry will be of the priming process in new paint booth.