Project: I-CAVS   -  
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Builder Name:paolo cavosi   -  
Project:   Vans - RV-10
Total Hours:2402.2
Total Flight Time:
Start/Last Date:May 28, 2019 - No Finish Date
Engine:IO-540 Thunderbolt Serial # EL-38135-48E
Propeller:MT Propeller MTV-12-B/193-53 serial 22G1268-K
Panel:Garmin G3X
 
Friendly URL: https://eaabuilderslog.org?s=I-CAVS

Home or Last Project Picture

Dec 20, 2023     10-24 Tailcone Step 3 - (1 hour) Category: Tail Feathers
Bolted both F636 Harness Anchors to the longerons F-1032. Torqued to 26 lbs/in and marked
 
Jan 27, 2023     10-21 Tailcone step 1-4 - (2 hours) Category: Tail Feathers
When i decided to mount the battery and bell crank support i realized that i installed the wrong platenuts. I installed all K1000-3 instead of K1000-8, therefore i had to drill out all the 8 platenuts and reinstall them. Not an easy task due to the position, but using the manual squeezer it worked fine.
 
Nov 20, 2021     11-10 Empennage Attach Step 4 - (2 hours) Category: Tail Feathers
disassembled the empennage and stored the subassemblies
 
Nov 18, 2021     11-10 Empennage Attach Step 1-3 - (1.5 hours)       Category: Tail Feathers
Installed the trim servo bracket assembly on the tailcone using clecos. Run the two bowden cable through Horizontal Stabilizer front spar and rear spar. Routed the cable through the elevator front spar through the inspection panels and connected to the trim tab horns.
Checked free movement and correct deflection +35�sides in up and in down position.
Positioned the servo in the Full Nose UP Position and checked both trim tabs deflected 35�
When positioning in neutral (right trim in trail with elevator) the left trim tab is down 3�h VANS if this is intended due to the differential Trim tab deflection or if both tabs need to be adjusted to be in trail on both sides when the trim is 0. In this case a small adjustment may result in less than 35� one or on both sides.
Adjusted the trim cable guide to compensate for the small difference in the trim tab trail position. Currently the two trim tabs are both aligning correctly to the trail position. Marked the trim cable to the right position.


 
Nov 18, 2021     11-9 Empennage attach step 2-6 - (3 hours)       Category: Tail Feathers
Preassembled the Trim servo assembly. Installed the trim assembly with Bowden cables on the tailcone. Reduced some play with different washer arrangement. Slightly filed the trim bell crank mount to allow free movement to full up and full down position.


 
Nov 13, 2021     11-6 Empennage Attach Step 2-6 - (2 hours)       Category: Tail Feathers
Installed both elevators to the Horizontal Stabilizer using temporary bolts. Checked travel +30 up and -25 Down. Need to adjust the 30. After brief conversation we decided to adjust the Elevator Up Stop F-1012D instead of trimming the horns as in case of replacement the HS block is easier to replace rather than the horns, which are more complex to remove in case of need. No need to adjust the F-1011B Down Stop doubler as the travel is exactly 25�

Final result is slightly over 30 UP and straight 25 for down.

There is no possibility for accidental jam of the Elevators horns in the Elevator Block. Therefore it is not necessary to apply the modification suggested in SB18-3-30.


 
Nov 13, 2021     11-5 Empennage Attach Step 1-5 - (1.5 hours)       Category: Tail Feathers
Measurement of the distance of the HS outboard rivets to the middle fuse rivet as indicated in the instructions. Always surprised about the precision of the assembly. VANS has been doing really a good job in designing the Kit in such a way that the measures are so precise. Certainly Lucio's help has been also instrumental in achieving the result.

After measuring and positioning we drilled #12 the attach brackets, the shims, the aft deck and the spacer and the angle using the attach brackets as drilled guides.
Lucios help in doing all this critical drilling has been really appreciated.

Bolted vertical stabilizer and final drilled #12 the 6 holes indicated. Bolted the Vertical Stabilizer according to indication.

MISSING: countersinking of bottom screw holes.


 
Nov 13, 2021     11-4 Empennage Attach Step 1-4 - (1 hour)       Category: Tail Feathers
Prepared the shims for the horizontal stabilizer attach brackets. Rigged the Horizontal Stabilizer to the tailcone. Final drilled #12 the Horizontal Stabilizer attach bars using the HS rear spar as guide.


 
Oct 18, 2021     11-3 Empennage attach step 1-12 - (5 hours)       Category: Tail Feathers
After mounting the elevators in trail position we used the bushing to match drill the horns through the VA-146 Elevator Center bearing. After that we removed the two elevators and final drilled the holes for an AN4 bolt using a #12 drill.
We reinstalled both elevators and secured both in trail position again.
We identified the most aft horn and removed again the elevators. In our case there was a minimal mismatch, with the right horn slightly back compared to the left. We defined the position of the pilot hole on the right elevator and we proceeded with the drilling of the horn.
After that we prepared a guide block using wood and two aluminium strips secured with pull rivets and we drilled the guide hole.
We drilled with 3/16" and after that with #12 drill for a AN3 bolt.
End result is very satisfactory and Lucio's support has been very valuable as always....avoiding the mess i could have done.


 
Oct 15, 2021     11-2 Empennage Attach step 1-4 - (2 hours)       Category: Tail Feathers
Positioning and securing the horizontal stabilizer required some time in order to get a good result. We (Lucio and I) decided slightly modify the indication provided by VANS.
1. We secured the Horizontal Stabilizer to the retractable part of the bench using clamps and the screws but with a slightly different setup for the 11/32 wooden shim.
2. we used two wooden planks to secure the elevators in trail position.
The rest of the activities is as indicated. Thanks to Lucio who fabricated a new bushing using a lathe...my attempt using the drill press were acceptable but the lathe allows a perfect fabrication.


 
Sep 21, 2021     6-4 step 7 VS rivet rear spar assembly SB-0001 - (1 hour)       Category: Tail Feathers
installation of SB-0001 (Service Bulleting 0001) regarding the Vertical Stabilizer Bottom Hinge bracket.
Drilled out the rivets. Final drilled TO WRONG size the bolt holes. Instead of #8 screw i drilled #10. Asked VANS and VANS replied on March 12 2001 indicating:
...Just heard back from engineering on this and they have approved the larger hardware #10 being used in place of the #8 screws. This will most likely require you to modify a washer in order to keep from having interference with the bend radius on VS-01010-1 Hinge Bracket but it is also acceptable."
Following that i ordered NAS1149F0364P (AN960-10) MS21042-3 and AN509-10R11.
Installed the hardware. It is not necessary to modify the washer as there is no interference with the radius on the bracket.
Torqued the screws at 42lbs/inch (28+14 friction). Marked all nuts with RED marker.


 
Aug 06, 2021     11-3 Empennage attach step 1 - (9 hours)       Category: Tail Feathers
After searching in the whole shop for the missing E-Drill Steel Bushing and not finding it i started searching all over again. The damn little thing is nowhere to find.
I asked Lucio for a possible alternative and he suggested to drill a AN4 bolt using a lathe....which i don't have. He commited to do that in the next week or so.

After few hours i decided to try myself using my drill press.
I started using a center drill and i determined the center of the bold using the hex head.
After that i inserted the bolt head down into the drill press. I positioned a very short #30 bit in the cross- table and i tried to have a correct vertical position.
I carefully drilled with a lot of lube and at the end i cut off the head and the threaded part of the bolt.
I repeated the whole drill for a second bolt obtaining a decent result.
After checking with Lucio the hole is acceptable in terms of concentricity and i will use the better bushing for the drill.


 
May 10, 2021     9-18 Elevators step 1-8 - (8 hours)       Category: Tail Feathers
Cut hinge, drilled first two #40 holes. Clecoed and matchdrilled the hinge on both elevators. Deburred all the holes. Started riveting on left elevator. One opps rivet used due to enlarged hole (countersinking). Riveted trim tabs and elevator spar hinge with manual squeezer for better accuracy. Trimmed hinge to measure and adapted the hinge pin. Hinge pin bending has been easier than expected. Safety Wire Missing.


 
May 02, 2021     9-17 elevators step 8-10 - (3 hours)       Category: Tail Feathers
riveted tab horns to trim tabs. Installed the foam ribs using tank sealant. Clecoed trim back spar and blocked the trim tab with clamps.
Riveted the side tabs with blind rivets. Waited for the sealant to cure


 
May 01, 2021     9-15 elevators step 7 - (0.5 hour)       Category: Tail Feathers
riveted trim cable attach brackets to trim cover plates using blind rivets.


 
Mar 18, 2021     12-3 Empennage Fairing Step 1-3 - (12 hours)       Category: Tail Feathers
Trimmed the bottom rudder fairing. Cut away the tail light as the position light are now in the Aveo Ziptips premiere. filled the hole with foam and covered with few layers of fiberglass. Sanded and filled imperfections with flox. Tedious process due to my inexperience with fiberglass and epoxy. I had to redo the steps a couple of times. End result looks satisfactory.


 
Mar 15, 2021     12-3 Empennage Fairing Step 5-11 - (24 hours)       Category: Tail Feathers
Work performed during the whole week.
Trimmed the stabilizer fairing (wrong cut, ended up with too big distance to elevator counterbalance). Decided to reconstruct the trimmed away part using foam and epoxy and fiberglass. Three layer on both fairings and some sanding and flox. End result is within tolerance, may need some additional final adjustment after final empennage assembly and rigging. Added aluminum strips to strengthen the fairing. Matchdrilled and final drill #30 for pop rivets.


 
Mar 08, 2021     12-2 Empennage fairing Rudder step 6-8 - (8 hours)       Category: Tail Feathers
Cut rudder top fairing to adapt to rudder. Matchdrilled the fairing (pushed forward, but probably not enough). Clecoed to the skin. Filled gaps with flox few times and sanded excess away. Due to my inexperience and due to a little kink in the counterweight area i sanded away some skin. I rounded the edges of the holes and filled with flox. End result is acceptable.


 
Mar 07, 2021     12-2 empennage fairing step 2-4 Elevator Fairing - (20 hours)       Category: Tail Feathers
Trimmed elevator fairings. Inserted in elevator tip and matchdrilled. Installed aluminum band with epoxy to strengthen the structure (aluminum 0.025). Final drilled #30. Used flox to make smooth transition to the skins. work done over a full weekend. Sanded many times and added flox many times.


 
Mar 03, 2021     9-15 Elevators step 8-9 - (2 hours) Category: Tail Feathers
Adapted both counterweights according to Kit Assembly Instructions.
 
Feb 10, 2021     9-17 Elevators step 1-7 - (2 hours) Category: Tail Feathers
After bending the tabs to a better result i proceeded with match drilling deburring and countersinking. Even if i used a handmade countersink jig to avoid wobbling around one of the countersink doesn't look good and may need an oops rivet.
in general more than happy with the end result.
parts are now ready for priming.
 
Feb 10, 2021     9-16 Elevators step 1-5 - (2 hours) Category: Tail Feathers
preparation of trim tabs (REDO) as the original ones where not up to my standard and i wanted to check if i was able to do it better than the first time.
Bends using the brake and the wedges turned out to be better than the first attempt.
Definitely more happy with the new tabs.
 
Feb 01, 2021     11-8 Empennage attach step 2-8 - (14 hours)       Category: Tail Feathers
Work done over few weeks, including priming session. Ordered new F-1095 components as the brackets have been mounted wrongly.
Final drilled according to instructions. Preassembled the F-1095B, F-1095A and F-1095C in order do have correct distance and alignment of all the parts. Installed on F-1095A with cleco and matchdrilled the F-1095C bracket in position. Completed match drilling of all the other components. Countersunk all rivet holes.
Deburred and primed all the parts. Final drilled #12 holes.
Primed all the parts, riveted all the parts and nutplates.


 
Oct 20, 2020     11-6 Empennage Attach Step 3-4 - (3 hours) Category: Tail Feathers
Cut the pushrod to measure. Instnstalled the VA-101 threaded insert and marked for the pull rivet holes.
Drilled holes, deburred edges and holes
Primed the parts.
Reinstalled the threaded insert and riveted in place with MSP-42. Installed rod end bearing MD3626 M with AN 316-6 jam nuts
 
Jul 06, 2020     9-17 Elevator step 4-6 final drill, dimple and countersink - (3 hours) Category: Tail Feathers
Elevator Trim part preparation
final drilled horns, spars and skins. dimpled the part for flush rivets
Countersunk spar.
Terrible result on the second spar with the cage wandering and making oval holes. Replacement ordered. Countersinking needs to be done by hand i don't trust the countersink cage anymore.
 
Jul 04, 2020     9-16 Elevator step 1-2 skin bend around spar - (1 hour)       Category: Tail Feathers
bending skin around elevator trim spar to 15°


 
Jul 04, 2020     9-16 Elevator Step 3-5 Bend skins and trim tabs - (3 hours)       Category: Tail Feathers
Prepared a little tool to bend the trailing edge as suggested in section 5. Performed the trailing edge bend together with Lucio.
Bending the skin tabs was a bit more difficult and the result has not been 100% satisfactory. I ordered spare skins to rebuild the trim tabs even after some gentle suasion the skins adapted to a more acceptable shape.


 
Jul 04, 2020     9-16 Elevator step 1-2 make clamping blocks and tab ribs - (4 hours) Category: Tail Feathers
Cut 6 clamping blocks out of wood as per dimensions indicated
Make the trim tab ribs from the PVC foam blocks. sanded smoothly.
 
Jun 20, 2020     11-8 Empennage Attach step 2 Fabricate Trim cable anchor brackets - (4 hours) Category: Tail Feathers
Marco Biagi to fabricate the anchor brackets according to drawing. Primed.
 
Jun 06, 2020     9-15 Elevator step 1-6 - (4 hours)       Category: Tail Feathers
Double flush riveting of the trailing edge has been easy, as both trailing edges were straight. Unfortunately i made one little dent in one of the skin, but it is nothing major.

rolling the leading edge has been a bit more muscular....We used a 1"" aluminum pipe and we rolled one section at the time, but still rolling the edge with four hands has been quite an effort.
The result is almost perfect and i cannot complain. Again working as a team and having an expert builder on your side is really making the difference.


 
Jun 01, 2020     9-14 ELEVATOR step 7-11 Trailing edge assembly and seal - (4 hours)       Category: Tail Feathers
Preparation of the foam ribs.

Setup for the trailing edge sealing:
Matchdrilled an aluminum angle and an aluminum bar for both trailing edges. Putting the trailing edge between the aluminium angle and the aluminum bar and using clecos in all holes keeps the trailing edge straight avoiding putting weights on the structure. Important to correctly position the aluminum angle so that the trailing edge is in contact with the inside of the aluminum angle. The aluminum bar is then checked on top keeping the two skins ""sandwiched"" and with constant pressure.

Applying the sealant with the syringe is pretty straight forward, you need only to pay attention to avoid touching too many things with the dirty gloves or tools....acetone cleans up the sealant pretty well.

After sealant is cured removing the angle and the bar is pretty tough as the sealant excess bonds the aluminum, however using a long blade and some patience and strong pulling it is relatively to separate the whole assembly

Thanks Lucio for the suggestion....

Cleaned all the holes and removed the excess with some acetone
Trailing edge look extremely straight


 
May 23, 2020     9-14 ELEVATOR step 1-6 - (3 hours)       Category: Tail Feathers
Closed the Elevator skins, riveting gusset to root rib and counterbalance rib assembly to main structure.
no specific issues found.


 
May 23, 2020     9-13 Elevator step 1-3 front spar riveting - (3 hours)       Category: Tail Feathers
Final inspection with Lucio on the work done. Lucio confirmed work was done well. I reported the error we made together riveting one elevator horn upside down.....He almost fainted and when i explained that i drilled out the rivets and riveted together the horn alone he wanted to check the result....As one rivet didn't look perfect we drilled it out and replaced, however the result didn't improve significantly. We resolved to keep it as it was.


 
May 23, 2020     7-12 Rudder step 1-5 - (2 hours)       Category: Tail Feathers
Final drilled all the parts for correct counterweight positioning.
riveted counterbalance rib to skins.
I removed few pop rivets that didn't look good and replaced them with new one. Cause of the badly looking manufactured head was a defective pop rivet puller that was promptly thrown to the waste bin.
Inserted last rivet on root rib skin thanks to Lucio's magic homemade bucking bar. This was also done on the left skin, avoiding the use of a pop-rivet.
Rudder is finally complete, after having completely scrapped the first attempt....The old rudder is still there as a practice sandbox to test difficult tasks like drilling out rivets and similar activities i need to practice.


 
May 23, 2020     7-11 Rudder Step 1-6 trailing edge back riveting - leading edge roll - (5 hours) Category: Tail Feathers
after several weeks after applying the tank sealant to the trailing edge i removed the clecos, cleaned all the excess and cleaned the holes for the rivets.
With help of Lucio i backriveted the trailing edge obtaining a very straight edge with a limited bulge to an excess of sealant i didn't squeeze away properly. In general the result is very good.
After that we prepared the rolling of the leading edge making sure the rudder was laying flat and using a 1"" aluminium pipe. We didn't bend the edges as suggested, however the result is very good.
Final activities were dedicated to the counterbalance weight positioning, match drilling and final bending of the skins. We resolved to avoid placing a rivet in the middle of the two screws and placing instead a screw with the corresponding K-1000-08 nut plate.
 
May 22, 2020     8-13 step 6-7 HS check rivets and complete HS - (3 hours) Category: Tail Feathers
After COVID restriction have been lifted i had finally the possibility to have Lucio inspecting the work done alone.
On the Horizontal stabilizer Lucio found only a 20-30 rivet that required a bit of rework and only 5-6 that he decided to drill out as the manufacturing head was protruding a bit.
Closing the Horizontal stabilizer with the pop riveter was a very easy task
 
Apr 11, 2020     9-12 Step 6 ELEVATOR blind rivet ribs halves - (2 hours)       Category: Tail Feathers
riveted both elevators using the LP4-3 blind rivets in all the locations indicated.


 
Apr 11, 2020     9-12 step 4 ELEVATOR Rivet second skin - (2 hours)       Category: Tail Feathers
Positioned skins in order to have correct nesting of E-1008B into E-1008A.
Clecoed all the ribs halves and the skin to the spar.
Riveted using the procedure indicated with the long bucking bar resting on the work bench edge.
Riveting the bottom left elevator has been fairly easy with no damage to skin and to spar.
Unfortunately for the top right elevator i got two little skin damages. in one case i had to drill out the rivet and replace. the rest worked ok.
Top skin of the left and right elevator in the trim cut-out area are NOT riveted as this will happen when the trim hinges will be positioned.


 
Apr 10, 2020     7-10 Step 3-6 RUDDER rivet bottom rib, spar and counterbalance rib - (2 hours)       Category: Tail Feathers
riverted striker to spar and horn (one rivet wrongly set, removed fairly easily after punching our mandrel),
riveted the skins to the spar, riveted the counterbalance rib and the top rib
Marked holes NOT to be riveted until counterbalance is in position.
STOPPED HERE WAITING FOR LUCIO BEFORE PROCEEDING ON THE COUNTERBALANCE.


 
Apr 09, 2020     7-10 step 2 RUDDER cleco front spar to shear clips - (0.5 hour)       Category: Tail Feathers
clecoed front spar to shears clips.
Primed the wto R-1007 stiker plates with Tempo Can Primer after cleaning and scuffing.


 
Apr 08, 2020     7-10 step 1 RUDDER clean tank seals on trailing edge holes - (1.5 hours) Category: Tail Feathers
cleaned tank sealant droplets on skin using acetone.
used deburring tool and a #40 drill to clean the holes.
Checked for alignement and it seems pretty straight with only two slight bulges at the top of the elevator.
 
Apr 07, 2020     9-9 step 8 ELEVATOR Scuffing for foam inserts - (1 hour)       Category: Tail Feathers
Necessary to mask the position of the foam insert and to remove the primer and to scuff the aluminimu surface for best adherence of the tank sealant


 
Apr 07, 2020     9-12 step 1-2 ELEVATOR rivet skin to spars - (2 hours)       Category: Tail Feathers
riveted the rear spar to the skin using the pneumatic squeezer on the trim cut out (AVOIDING THE TOP SIDE BECAUSE OF THE TRIM HINGE...marked with RED Tape)


 
Mar 31, 2020     8-13 Step 4-5 Rivet skins to stringers - (3 hours)       Category: Tail Feathers
Riveted stringer to skins, drilled out a couple of rivets. I found pretty difficult to achieve consistent result in the riveting due to the narrow space in the different location at the stringer position. the outer areas were easier to do, but riveting alone has not been an easy task and i had to drill out few rivets.
i resolved to wait before closing completely the structure in order to have the opportunity to cross check with Lucio the quality of the work.


 
Mar 30, 2020     8-13 Step 2-3 HS Rivet skin to ribs and stringers - (8 hours)       Category: Tail Feathers
rivet skin to inboard ribs HS1004 up to the stringers on left and right, top and bottom skins
riveted ribs to the skin


 
Mar 29, 2020     9-11 step 3-6 ELEVATOR Rivet E-1008 B Halves to spar on both sides - (2 hours)       Category: Tail Feathers
Riveted with squeezer the rear spar to the E-1008B halve on the right elevator (bottom skin) together with Lucio. Riveted the shear clips in the right position

Riveted with the squeezer the rear spart to E-1008B halves on the left elevator (TOP Skin).
One rivet on shear clip not good. Drilled out with some difficulties. slightly enlarged hole. Riveted with bucking bar with better result.
RIveted shear clips and gussets to spar


 
Mar 25, 2020     7-9 step 2-8 RUDDER Tank Sealant and Rudder Blind riveting - (2 hours)       Category: Tail Feathers
apply tank sealant on trailing edge. Help from Riccardo to hold skin and position correctly
Position the right and left skins in a way that the stiffeners nest appropriately (left stiffener aft end on top of the right stiffener and both forward end below the shear clip).
Use blind rivets LP4-3 and cleco as we go.
First rivet wrongly set, however easy to remove and replace (mandrel knocked out before drilling).


 
Mar 17, 2020     8-13 step 1-2 HS Rivet skins to front spar web - (5 hours)       Category: Tail Feathers
Riveted with flush rivet set all the nose ribs to the skin using flush rivets.
Need to drill out a couple of rivets, but in general fairly satisfied with the result
Just a couple of rivets are not perfect, however i dont risk drilling them out and create a larger hole (i had to use a couple of oops-rivets).
Riveted the skin to the front spar started from the inside and moving outside.
A little bit difficult to drive some of the rivets, some scratching on the spar primer, but apparently not a big deal.
There is a small gap between the spar flange and the skin and in some places a back light filters through.
Problem highlighted by Lucio and i asked VANS technical support for advice.
Response came very quickly from Gay Kayser indicating that the possible reason is too shallow countersinking (0.002 in, that is two clicks on the countersink cage), however Gary confirmed that this is not an issue and that it is not a big deal.
********************* Email from Gary Keyser****************************************
Il giorno 18 mar 2020, alle ore 15:33, Gary Keyser ha scritto:
Paolo
So this is on the leading edge of the outer wing skin? If so do not worry about it and move on.
Ciao
Gary
********************


 
Mar 16, 2020     8-13 step 1 HS Rivet inspar ribs - (0.5 hour)       Category: Tail Feathers
riveted inspar ribs HS-904 with LP4-3 pull rivet.


 
Mar 15, 2020     8-12 step 1-2 HS Skin on cradles and cleo structure rivet front ribs - (4 hours)       Category: Tail Feathers
positioned skins in the cradles. clecoed all front ribs to the skins.
started riveting with flush rivets.
Using the rivet swivel set didnt really help setting good rivets. I had to drill out a couple.
Changed to flush-rivet set and it worked better, although i pushed a bit too hard in two spots (skin is slightly deformed around a couple of rivets, but no major dents.
Rivets on the Inspar ribs (AN470AD4-7 and 8) are not very well set. little marring due to the squeezer.
Drilled out a bad rivet with angle drill (not easy to access) and replaced with slightly better results.
CHECK WITH LUCIO on the RIVETS on HS-905 Inspar Nose RIBS.


 
Mar 14, 2020     8-11 Step 1-3 HS Riveting Inspar ribs - (1.5 hours)       Category: Tail Feathers
assembled inspar ribs to Stringer web assembly.
Rivet inspar ribs to the structure using pneumatic squeezer
inserted snap busing into 5/8"" holes
Manufactured Head of rivets OUTSIDE in order to have easier drill-out option in necessary as indicated in MIL-R-47196A(MI) (3.3.3.1 Head direction. Unless specified on the engineering drawing or specification, the manufactured head of the rivet shall be located on exterior surfaces.)


 
Mar 12, 2020     8-10 Step 1-2 HS Rivet Stringer and Stringer web assembly - (2 hours)       Category: Tail Feathers
Preassembled the HS-1004 ribs, the HS-1016 stringer web and the two HS-1014 and HS-1015 stringers.
Riveted all componens with AN470AD4-4/5 rivets using pneumatic squeezer


 
Mar 12, 2020     8-2 step 6 HS Rivet HS-912 Hinge Brackets - (0.7 hour) Category: Tail Feathers
Final drilled all Hinge Brackets with #30 drill bit.
Countersunk holes as indicated in order to rivet with AN4264-6 and to accomodate the bearing assembly.
 
Mar 12, 2020     8-2 step 5 HS Rivet HS-906 doubler to rear spar - (1 hour) Category: Tail Feathers
Rivet HS-906 doubler to HS rear spar using An4704-6 rivets.
Used pneumatic squeezer with good results
 
Mar 12, 2020     8-6 step 1-2 HS rivet HS doubler, Front Spar and brackets - (2 hours)       Category: Tail Feathers
Preassembled front spar with HS-1002 with front spar caps HS-10013 and front spar attachment brackets HS-1008 L&R.
Rivetd with different types of rivet depending on thickness of material. Final drilled few holes to #30.
All the rivet have been set using the pneumatic squeezer with very good results.


 
Mar 12, 2020     8-3 Step 2 HS Bolt Hinge Bracket assembly to rear spar - (0.5 hour) Category: Tail Feathers
Consulted torque table on section V (page 5-20)
Determined the friction drag torque on the nyloc nut around 5-6 Inch/pounds
Added the 6In/lbs to the self locking nut torwue value (28 in/lbs) and final torqued at 34 in/lbs.
CHECK IF VALUES ARE CORRECT WITH LUCIO. POSSIBLE SLIGHT OVERTORQUE BECAUSE OF USING THE SELFLOCKING TORQUE VALUES INSTEAD OF THE NORMAL AN365 (20-25 in/lbs).
 
Mar 11, 2020     7-7 step 3-4 RUDDER rivet reinforcement plates to spar - (0.5 hour)       Category: Tail Feathers
Rivet R-608PPand R-607PP reinforcement plates to R-1002


 
Mar 11, 2020     7-9 step 1 RUDDER rivet R-1010 shear clip to stiffeners - (0.5 hour) Category: Tail Feathers
Rivet R-1010 Shear clips to stiffeners using LP4-3 bling rivet
 
Mar 11, 2020     7-8 step 1-2 RUDDER back rivet top and bottom rib - (1 hour) Category: Tail Feathers
Back rivet top rib R-1003A and R-1003B to both skins.
Back rivet R-1004 Bottom rib assembly to right skin
 
Mar 10, 2020     7-7 step 5 RUDDER back rivet stiffener to skin - (2.5 hours)       Category: Tail Feathers
As the first Rudder didn't meet my expectation, here the rebuild of the rudder with brand new parts and professional priming.
Back rivet all stiffeners R-1015 to R-1001


 
Mar 07, 2020     9-10 step 2-7 ELEVATOR tips riveting and spar doubler riveting - (4 hours)       Category: Tail Feathers
Assembled and riveted Tip ribs with counterbalance skins.
Lucio teaching riveting with the squeezer and with the rivet gun.
Riveted all the Hinge Reinforcement plate on the Elevator front spar and all the nutplates.
Riveted the Elevator Horns tot eh Spar and Inboard ribs


 
Mar 07, 2020     9-11 step 1-2 ELEVATOR rived reinforcement horns and root ribs - (4 hours)       Category: Tail Feathers
Backriveting of the reinforcement plates to the elevator bottom skins. Lucio teaching and supervising. Marco preparing parts and positioning during back riveting
Backriveting of all the ribs halves to the skins
Lucio took care of riveting the E-1007 rear spar (only one side and only up to the trim section-
Further work pending to complete step 3


 
Mar 07, 2020     9-9 step 7 Elevator bend skin edge Category: Tail Feathers
My previous attempts to slightly bend the skin edges as indicated resulted in a poor result. My rolling edge bending tool doesnt seem to be an easy tool to work with resulting in weavy skins. After some consultation with Lucio I accepted his suggestion to skip this step as the risk to create a ondulated skin seems to high compared to the benefits.
 
Feb 20, 2020     PRIMING Vertical and Horizontal Stabilizers, Rudder and Elevators - (10 hours)       Category: Tail Feathers
Cleaning with Acetone all the parts
Primed with AKZO Nobel Aeronautical Primer with specialized assistance.
I got the support from a friend who provided the necessary specialized assistance and the equipment.


 
Feb 17, 2020     PRIMING SESSION Surface preparation 2nd round - (8 hours) Category: Tail Feathers
Scotchbrite and sanding of all the parts for
Elevator
Vertical Stabilizer
Horizontal Stabilizer
Rudder
 
Feb 16, 2020     EMPENNAGE PRIMING PREPARATION - (9 hours) Category: Tail Feathers
Scotchbrite and sanding of all the parts for
Elevator
Vertical Stabilizer,
Horizontal Stabilizer
Rudder
 
Feb 01, 2020     9-8 step 2-3 ELEVATOR Countersink and dimple E-1007 Spar - (2 hours) Category: Tail Feathers
Due to a mistake the E-1007 spars presented visible ondulation (waves). Decided to reorder and to replace both E-1007.
Angle check together with Lucio and countersinking of all the necessary holes.
Dimpling according to indication.
 
Feb 01, 2020     9-9 step 1 ELEVATOR check angle front/rear spars - (0.5 hour) Category: Tail Feathers
due to the dimpling of the new E-1007 elevator spars the plan requires an angle check and small adjustments if necessary.
No adjustments necessary and the requested angles have been checked.
 
Jan 31, 2020     9-5 step 1-4 ELEVATOR reassembly everything with Lucio crosschecking everything - (3 hours) Category: Tail Feathers
Reassembled all the Elevators parts together with Lucio in order to check everything.
Disassembled and marked all the parts for priming
 
Jan 11, 2020     9-9 Step 4-5 ELEVATOR dimple tip ribs assembly - (2.5 hours) Category: Tail Feathers
dimpled ribs flanges and both ribs of each side with #30 die and flanges with #40 die
 
Jan 11, 2020     9-8 step 4 ELEVATOR dimple flange on root ribs - (1 hour) Category: Tail Feathers
dimpled the root ribs and the webs of the elevator ribs
 
Jan 06, 2020     9-7 step 9 ELEVATOR Dimple skins - (3 hours) Category: Tail Feathers
dimpled all the skins and the relevant ribs for 3/32 rivets
 
Jan 06, 2020     9-8 step 1-3 ELEVATOR dimple and countersink parts - (2 hours) Category: Tail Feathers
Countersink front spars both sides for 3/32 skin dimples.
Dimpled rear spars for 3/32 skin dimples.
countersink inboard holes on TOP flange of the rear spars, dimple the rest.
dimple also three holes in front spars and two holes in rear spars for the inboard ribs (3/32 rivets).
 
Jan 06, 2020     9-7 Step 8 ELEVATOR deburr holes and edges - (4 hours) Category: Tail Feathers
Deburr all the components together with Marco Biagi.
 
Jan 06, 2020     9-9 step 6 ELEVATOR countersink trailing edge wedge - (1.5 hours) Category: Tail Feathers
Using drill press we countersunk the trailing edge wedge on both sides of each elevator perpendicular to the skin (drill press adiusted -12�rom the vertical.
 
Jan 06, 2020     9-9 step 1 ELEVATOR checking spar flange angles - (1 hour) Category: Tail Feathers
Flange angle in the front spar should be 84�rear spar should be 96�br>My measurement indicated a 1-2 degrees discrepancy and both rear spars had an ondulation probably done when using the pneumatic squeezer.
Tried to straighten out the flanges but didnt improve.
DECISION: Reorder Spars and substitute.
 
Jan 04, 2020     9-7 step 7 ELEVATOR disassembly and mark - (3 hours) Category: Tail Feathers
completely disassemble and mark all parts
 
Jan 03, 2020     9-7 step 4 ELEVATOR trim tab anchor brackets final drill - (0.5 hour) Category: Tail Feathers
prepared the trim cable anchor brackets and drilled the cover plates according to drawing.
final drilled with #30 drills
 
Jan 03, 2020     9-7 step 5-6 ELEVATOR trim cover plate nut plate drill - (1 hour) Category: Tail Feathers
Final drilled the holes for the nutplates K1000-06 with #28 drill bit (checked on several manuals).
Dimpled the skin with dimple die #6 for screws.
Dimpled the skin on the outside for 3/32 flush rivets.
Dimpled all the K1000-06 nuts to accept the dimple in the skin.
 
Jan 03, 2020     9-7 step 3 ELEVATOR skin trailing edge match drilling with - (3 hours) Category: Tail Feathers
Final drill all skin holes with #40 drill.
Using the 84�ig on the trailing edge final drilled the trailing edge assembly.
 
Jan 02, 2020     9-6 step 1-2 ELEVATOR trim access plate match drill - (0.5 hour) Category: Tail Feathers
Preassembly trim access plate and trim reinforcement plate. Matchdrilled holes in skin
 
Jan 02, 2020     9-6 step 5-8 ELEVATOR tip rib and closing skin preassemble - (1 hour) Category: Tail Feathers
Preassembled and matchdrilled Tip Rib and counterbalance rib and skin. Preassembled top skin, inserted trailing edge wedge after adapting to measure.
 
Jan 02, 2020     9-6 step 3-4 ELEVATOR spar / root rib gusset - (5 hours) Category: Tail Feathers
position gusset on spar and root rib. carefully matchdrilled both sides
 
Jan 02, 2020     9-7 Step 1 ELEVATOR skin close out tabs matchdrilling - (0.5 hour) Category: Tail Feathers
matchdrilled skin close out using #30 drill.
 
Jan 02, 2020     9-5 step 3-4 ELEVATOR preassemble and match drill - (2 hours) Category: Tail Feathers
matchdrilled skins with #40 drill
 
Jan 02, 2020     9-7 step 2 ELEVATOR match drill skins (partial) - (1 hour) Category: Tail Feathers
matchdrilled skins with #40 drill
 
Jan 02, 2020     9-7 step 2 ELEVATOR horns preassemble and match drill - (0.5 hour) Category: Tail Feathers
match drilled horns on both elevators
 
Jan 01, 2020     9-3 step 1-3 ELEVATOR skin preparation and bending - (1.5 hours) Category: Tail Feathers
Prepare skins, Bending according to drawing, deburring skins
 
Jan 01, 2020     9-5 step 1-2 ELEVATOR reassembly and match drill - (2 hours) Category: Tail Feathers
preassembly and matchdrill ribs to rear and front spars
 
Jan 01, 2020     9-4 Step 1-3 ELEVATOR front spar preparation - (1.5 hours) Category: Tail Feathers
Drilled 5/8"" holes for cable routing. preassembled and deburred sapr doublers
 
Jan 01, 2020     9-2 STEP 4-6 ELEVATOR Counterbalance rib reassembly - (1.5 hours) Category: Tail Feathers
Tip Rib preassembly and matchdrilling
 
Dec 31, 2019     9-2 step 2 ELEVATOR deburring parts and preparing - (7 hours) Category: Tail Feathers
prepare and deburr elevator parts.
 
Dec 23, 2019     20-4 Bottom Wing Skins left and right step 2-6 - (9 hours) Category: Tail Feathers
prepared flap gap stiffener for both wings.
Preassembled W-1021 flap fairing and W-1024 aileron fairing for both wings. Final drilled all the holes, disassembled all parts, deburred all holes.
Countersunk holes on the rear spar assambly and dimpled the fairing as indicated.
Primed all the parts with Ekopoxy primer (two coats).

After curing riveted all the parts. Few rivets missing in the wing root rib area as it is difficult to rivet without an helping hand.
 
Dec 18, 2019     9-2 step 7 ELEVATOR Shear clips separation - (1 hour) Category: Tail Feathers
separate and prepare shar clips, final drilling #30
 
Dec 18, 2019     9-2 step 1-2 ELEVATOR deburr ribs, shear clips, skins and spars - (4 hours) Category: Tail Feathers
separate ribs, deburr ribs, skins, spars and shears
 
Dec 15, 2019     8-9 Step 8 HS Countersink Spars and stringers - (4 hours) Category: Tail Feathers
countersink flanges of front and rear spars and the 3/32"" holes in the stringers.
 
Dec 14, 2019     8-9 Step 7 HS Dimple skins and flanges - (7 hours) Category: Tail Feathers
dimpled skins (CHECK PROPER SIDE) and rib flanges AVOID DIMPLING fairing holes.
 
Dec 03, 2019     8-9 Step 5 HS Mark parts and disassemble - (2 hours) Category: Tail Feathers
mark all parts in order to reposition in the same way
mark all fairing holes NOT TO BE DRILLED AND DIMPLED

disassemble all the parts
 
Dec 03, 2019     8-9 Step 4 HS Final drill skins #40 - (4 hours) Category: Tail Feathers
MARK Empennage fairing holes.
AVOID DRILLING DIMPLING these holes
Final drill all skin holes EXCEPT THE FAIRING HOLES
 
Nov 23, 2019     8-8 step 1-4 HS Preassembly HS Structure - (3 hours)       Category: Tail Feathers
Cleco nose ribs to front spar assembly. final drill 1/8"" holes in the aft flange.
Cleco two inboard inspar ribs (type B) match drill.
Cleco other ribs and final drill alls the holes.
marked all ribs in order to make sure to reassembly in the same location
Work done together with Lucio and Marco


 
Nov 23, 2019     8-8 step 6-8 HS Preassembly Horizontal Stabilizer - (2 hours) Category: Tail Feathers
Clecoed front ribs to skin
 
Nov 23, 2019     8-9 Step 1-3 HS Final drill structure - (2 hours) Category: Tail Feathers
assembled stringers to web. final drilled #30 the 5 outboard holes on each stringer.
final drilled all #30 holes in commn with the spar, stringer, caps.
 
Nov 23, 2019     8-8 Step 5 HS deburr skins and prepare for reassembly - (2 hours) Category: Tail Feathers
prepared skin for preassembly. deburred all the edges
 
Nov 23, 2019     8-7 Step 2 HS Bend two inspar ribs - (0.5 hour) Category: Tail Feathers
bend two inspar ribs 9�r>done with Lucio
 
Nov 21, 2019     8-7 step 5 HS fabricate 4 cradles - (2 hours)       Category: Tail Feathers
fabricated 4 cradles for the horizontal stabilizer assembly


 
Nov 20, 2019     6-6 step 9B VS redone rivets with Lucio's Support       Category: Tail Feathers
Lucio Castrogiovanni concurred in removing few rivets and in redriving them.
Result is now much better especially for a rivet on the bottom hinge.
Vertical stabilizer can be considered complete, unless we i decide to replace some bad rivets with structural MKS Rivets.


 
Oct 27, 2019     8-7 step 1 HS prepare inspar ribs - (1 hour) Category: Tail Feathers
deburr all the edges and if necessary fluted the ribs to make them flat
 
Oct 27, 2019     8-7 step 3-4 HS nose rib preparation - (4 hours) Category: Tail Feathers
deburr all edges including lightening holes.
Radius corner the forward end to prevent denting the skin
ON ONLY TWO RIBS: bend the flange about 9�br>no fluting necessary. Ribs came already straightened and fluted
 
Oct 27, 2019     8-5 step 8 HS Disassemble mark and prime spars - (3 hours) Category: Tail Feathers
Disassemble all components, deburr all holes and edges. Mark all parts.
Clean with Ekoclean and rinse with water.
Primed with Valspar Prime zinc-chromate self etching primer.
 
Oct 25, 2019     8-6 step 3-4 HS prepare inspar ribs type A and B - (0.5 hour) Category: Tail Feathers
identified the 4 inspar ribs. removed in the first group only two flanges (type A) and removed all the flanges in the second group (Type B).
 
Oct 25, 2019     8-5 step 6-7 HS Countersink front spar doubler and final drill - (1 hour) Category: Tail Feathers
Countersunk identified 1/8"" holes on the Front Spar Doubler for 1/8"" flush rivets.
Final drilled the middle 9 holes in bot flanges with #40 drill, then machine countersunk for 3/32"" rivets.Same procedure on the other flange.
 
Oct 24, 2019     8-5 step 3-5 HS Front spar doubler and attachment brackets - (1.5 hours)       Category: Tail Feathers
Deburred all edges of doubler and front spar L and R attachment brackets.
After clamping a flat thick aluminum angle to the L&R attachment brackets, matchdrill with #30 drill 8 holes from spar into the attachment brackeds.
Final drill the other 1/8"" holes in spar and doubler with #30 drill. CAREFUL ON THE MARKED DONT DRILL.


 
Oct 24, 2019     8-3 step 3 HS Elevator attachment bracket fabrication - (2 hours) Category: Tail Feathers
cut from AA6-187X2X2-1/2 angle two parts
Drilled 1/8"" hole in the indicated position.
Trimmed to measure.
Drilled 3/16"" holes
Radius all corners 1/8"".
After mounting and matchdrilling the holes are right at the limit to the edge.
After consultation with Lucio Castrogiovanni it seems that the fabrication is acceptable.
As i ordered other angles from VANS i consider to refabricate the brackets.
 
Oct 22, 2019     8-5 step 2 HS Spar caps deburring - (2.5 hours) Category: Tail Feathers
Disassembled, deburred, removed chips on all sides and holes.
Reassembled in position
Same procedure for the other spar cap.
 
Oct 21, 2019     8-5 step 1-2 HS Spar Caps final drill - (2 hours) Category: Tail Feathers
Nested spar caps to spar, measure distance, mark and cleco in position with additional clamps.
Final drill the 1/8"" holes in the spar web into the entire length with #30 drill.
Disassembled, deburred, removed chips on all sides and holes.
Reassembled in position
Same procedure for the other spar cap.
 
Oct 19, 2019     8-4 step 1-2 HS Trim Front Spar Caps, long and short stringers - (2.5 hours) Category: Tail Feathers
Trim material (Shaded in the instruction), file and deburr all edges of spar cap and stringers
 
Oct 19, 2019     8-2 step 1-4 HS rear spar assembly & Prime - (5 hours) Category: Tail Feathers
Deburring all parts including lightening holes
Matchdrill holes from spart into doubler #30 drill
Final drill all the other 1/8"" holes with #30 drill
Machine countersink holes on spar. Mark holes NOT TO BE Drilled
Final drill #12 wht 3/16"" holes in the hinge brackets.
Cleco hinge brackets and final drill#30 into spar.
Scuffed the hinge brackets. Cleaned all parts with EkoClean.
Primed with Valspar Self Etching ZincOxide Primer green
 
Oct 19, 2019     8-3 step 1 HS inboard hinge bracket - (0.5 hour) Category: Tail Feathers
final drill the six holes of the two flanges with #30 drill. final drill the 3/16"" with #12 drill.
Scuffed all the parts.
Clamped to a flat and riveted with 1/8"" rivets
 
Oct 08, 2019     7-11 step 5 RUDDER Straigthened rudder trailing edge - (1 hour) Category: Tail Feathers
Carefully straigthened rudder trailing edge waviness due to wrong pressure setting of squeezer and wrong use of flush rivet set.
Not sure this may be acceptable. Reordered all the pieces for the Rudder. Will check with builder support if that could be considered acceptable (i doubt it because of the hard banging)
Following conversation with Lucio Castrogiovanni (Builder of an RV7) it seems that the construction has an acceptable level, however i decided to reorder all the part and rebuild the rudder
 
Oct 02, 2019     6-6 step 7 VS rivetd spar flanges of bottom ribs. - (1 hour) Category: Tail Feathers
clecoed back the bottom rib. riveted (squeezer) the bottom rib AVOIDING fairing screw holes.
 
Oct 02, 2019     6-5 step 3 VS rivet vertical stabilizer structure - (1 hour) Category: Tail Feathers
preassembly of Vertical Stabilizer structure with clecos.
Rivet top and middle rib. Clecoed ONLY bottom rib to facilitate access for skin riveting
 
Oct 02, 2019     6-6 step 3 and 4 VS rivet top rib and clecoed bottom rib - (1 hour) Category: Tail Feathers
rivetd top rib only forward of front spar. reinstalled CLECO ONLY bottom rib
 
Oct 02, 2019     6-6 step 8 VS rivet skin to rear spar - (0.5 hour) Category: Tail Feathers
riveted with squeezer the skin to the rear spar avoding LAST HOLE.

Mark all holes NOT TO BE RIVETED on top and bottom rib and on the spar with RED TAPE
 
Oct 02, 2019     6-6 step 6 VS rivet skin to middle rib and top rib - (1 hour) Category: Tail Feathers
riveted the skin to the middle inspar rib and the remain of the top rib (Squeezer).
 
Oct 02, 2019     6-6 step 5 VS rivet skin to front spar - (0.5 hour) Category: Tail Feathers
riveted the skin to the front spar. difficult access. removed some clecos to guarantee access to top area. Drilled out a couple of bad rivets. used 2 oops.-rivets, however result was not much better.
 
Oct 02, 2019     6-6 step 9 (redo) VS rivet rear spar caps to spar - (1.5 hours) Category: Tail Feathers
riveted with squeezer, but very bad results. had to drill few rivet out.
Redone with bucking bar and with rivet gun.....results barely acceptable. Probably too high pressure and not perfect alignement.
Drilled out 7 rivets and replaced 2 with ooops rivet.
Riveted again the bottom hinge with Lucio's Help
Review rivets with Lucio Castrogiovanni, drilled our few more rivets, redriven rivets on 20 / 11/ 2019
Building planes and making new friends. A local member of the Homebuilt Association in Italy is an happy owner of an RV-8 and offered his knowledgable support for my build. I really appreciate the cooperation spirit of the homebuilders. Lucio is an extremely knowleadgeable person and is always happy to help.
Starting with some rivet replacement and basic instruction.
 
Oct 02, 2019     6-6 step 2 VS rivet middle nose rib forward - (1 hour) Category: Tail Feathers
removed bottom rib. riveted forward part of bottom rib. difficult to rivet without clear view.
After inspection few rivets are protruding a little bit.
Inside the rivets look more or less ok, however i am considering to drill out some and replace with blind rivets....consultation is needed. maybe with some filler it will not be noticeable.
 
Oct 02, 2019     6-6 step 1 VS cleco skin to structure - (1 hour)       Category: Tail Feathers
clecoed skin to structure. Clecoed each hole


 
Sep 25, 2019     7-10 step 3-7 RUDDER rivet bottom and top ribs - (2.5 hours) Category: Tail Feathers
rivet bottom rib assembly and striker plates to spar.
Rivet top rib to spar
**Rivet skins to spar flanges ....LEAVE TWO HOLES OPEN FOR COUNTERBALANCE RIB
Rivet counterbalance rib to spar
rivet holes left open in **
rivet skin to top and counterbalance rib with EXEPTION three forward holes
 
Sep 25, 2019     7-11 step 2 RUDDER Leading Edge - (2 hours) Category: Tail Feathers
In spite of considering the need to rebuild the rudder from scratch i decided to roll the leading edge in order to practice a bit.
Result is barely satisfactory. Lessons learned
1. get help. doing it alone is not trivial.
2. the 1 1/4 diameter pipe is not easy to find in italy and i resolved with a slightly bigger diameter....wrong decision as the rolling is not sufficient.
3. get a very sturdy pipe, otherwise the cleo will tear it apart. Gorilla tape may work, but i didn't have any.
4. work only if you have the right set up and tools. don't hurry
 
Sep 25, 2019     7-11 step 1 RUDDER double flush rivet trailing edge - (4 hours) Category: Tail Feathers
Instead of following the instruction i decided to follow what appeared to be a good way to make the trailing edge perfectly straigth. The reason was that my trailing edge skins were already a bit weavy and i thought more precision was required.
The idea to have an aluminum angle to cleco the trailing edge to is good, however my use of the squeezer has been less than perfect resulting in a very heavy trailing edge.
Drilled aluminium reference angle with stepdrill to allow 1 inch hole for pneumatic squeezer.
Used pneumatic squeezer with adapted flat die trimmed to angle.
Result not satisfactory as trailing edge presents barely acceptable waves (within recomended tolerance, but very bad look).
DECISION: REORDER COMPONENTS AND REDO THE RUDDER:
 
Sep 24, 2019     7-7 step 3 RUDDER rivet reinforcement and nutplates to spar - (1 hour) Category: Tail Feathers
riveted reinforcement to spar and K1000-6 to the reinforcement plate.
Repeated the operation for all three Reinforcement Plates and nutplates.
 
Sep 23, 2019     6-5 step 1-2 VS rivet top hinge brackets and front spar doubler - (2 hours) Category: Tail Feathers
rivet VS1017 doubler to VS1003 rear spar
CAREFUL ON RIVET TO USE, PAY ATTENTION TO THE TWO HOLES BETWEEN THE HINGE BRACKETS: FIRST RIVET THE TWO HOLES THEN RIVET HINGES IN PLACE
Rivet top hinge bracket VS1017 to rear spar.
Rivet VS1015 to VS1002 front spar.
 
Sep 23, 2019     7-10 step 1-2 RUDDER Rivet spar to shear clips - (2 hours)       Category: Tail Feathers
remove clecos from trailing edge, clean with #40 drill (manually).
cleco spar to shear clips
Rivet the spar to shar clip with LP4-3 in each shear clip


 
Sep 22, 2019     6-4 step 7 VS rivet rear spar assembly - (2.5 hours) Category: Tail Feathers
rivet rear spar assembly using pneumatic squeezer.
results are not bad but i am still struggling to understand how to handle the squeezer....again i discovered months later that you need to keep the squeezer very well aligned with the rivet and that there are few tricks to do that.
 
Sep 21, 2019     7-9 step 1-8 RUDDER assembly rudder, blind rivet stiffener - (3 hours)       Category: Tail Feathers
Prepare aluminium angle as reference for trailing edge.
Apply 3M doubleside tape to both sides of trailing edge R-1006 wedge.
Rivet stiffener and shears clip R1010A-G Left and Right to R1005A-G using LP4-3 blind rivets
Cleco skins, trailing wedge and aluminium angle reference together.
Clecoed every single hole.
Add weights to the 4"" board on top of rudder.


 
Sep 18, 2019     6-4 step 5 VS prime and assembly - (4 hours)       Category: Tail Feathers
clean with ekoclean, apply ekoetch and prime with Ekopoxy.
Second round of priming for second Vertical Stabilizer


 
Sep 15, 2019     7-8 step 1-3 RUDDER Top rib, bottom rib back riveting - (2 hours) Category: Tail Feathers
back rivet top ribs halves R1003A&B to R1001L&R skins.
back rivet R1004 assembly to right skin R1001R.
 
Sep 15, 2019     7-7 step 1-2 RUDDER Rivet Spar, Doubler, Horn and Bottom Rib - (1.5 hours)       Category: Tail Feathers
Rivet Horn Assembly (nutplate)
Rivet Bottom RIb halves


 
Sep 15, 2019     7-7 step 5 RUDDER back rivet stiffener to skin - (2.5 hours)       Category: Tail Feathers
Backriveting stiffeners to rudder skin.
Work seems to be easy and the result looks good.
However as i discovered months later it is much better to work with lower gun pressure (around 30-35 PSI) and on this first attempt the pressure was higher resulting in more difficulties controlling the rivet gun.


 
Aug 14, 2019     7-6 step 13 RUDDER Clean and Prime rudder parts - (4 hours) Category: Tail Feathers
Ekoclean, Ekoetch, Ekopoxy all parts (support laura and riccardo)
 
Aug 11, 2019     6-4 step 1-4 VS front spar doubler, rudder stop preparation - (2 hours) Category: Tail Feathers
VS1015 and VS1002 assembly, final drill, deburr. dimple.
Fabricate rudder stops R1007A&B, matchdrill
 
Aug 10, 2019     6-3 step 6-11 VS dimple VS skin, ribs, spars - (8 hours) Category: Tail Feathers
Dimpleed holes in VS-1001, all ribs side flanges, countersunk deeper 0007"" (refer to manual Section V) in order to accomodate skin, mark rudder hinges, final drill VS-1010, VS1011, VS1012. deburred all holes
GOTCHA: spar hole corresponding to last hole on skin has been countersunk by mistake in step 8.
Disassembled all parts and mark all the parts
Deburred all the parts
Dimpled flange holes Vs-1003 above the machine countersunk holes
Final drill #12 all hinge single holes
 
Aug 10, 2019     7-6 step 12 RUDDER countersink trailing edge for skin - (2 hours) Category: Tail Feathers
countersink perpendicular to edge (adjust Bench Drill to 12� allow for skin 0.007"" deeper than normal.
Remember that 1 click on the countersink cage is 0.001"".....therefore 7 clicks from normal flush position.
Cross check with small gauge (dimpled skin piece)
Marco Biagi joined the construction group
 
Aug 09, 2019     6-3 step 3-5 VS assemble, final drill dimple skins and structur - (5.5 hours) Category: Tail Feathers
I have received the parts ordered after screwing up with the countersink and bad priming therefore i can reprocess the steps.
Reassembled structure, finaldrilled all holes. Marked all the parts.
Marked all the fairing holes NOT TO BE DIMPLED MARK CORRESPONDING HOLES ON SKIN; FLANGES AND RIBS.....
CAREFUL ON NOSE RIBS. If necessary trim the nose ribs to avoid dents in skin
 
Aug 09, 2019     7-6 step 8-11 RUDDER skind bend, disassemble and debur - (5 hours) Category: Tail Feathers
Skin bend with wheel bending tool (MISTAKE)
Dimpled the skins, but the weaviness of the trailing edge is really worrisome.
I used the bending wheel tool wrongly, probably too much pressure.
I will give it a try and rivet the whole thing together, but i believe the result will not be acceptable. I consider this as a kind of expanded training kit from VANS.
 
Aug 07, 2019     7-6 step 4-7 RUDDER assembly trailing edge - (4 hours) Category: Tail Feathers
prepared the tool 84�o drill trailing edge perpendicular to the cordline (not the skin).
pre-assembled trailing edge.
matchdrill using 84�ol on trailing edge.
 
Aug 05, 2019     6-4 step 5 VS remove primer from VS assembly. - (8 hours)       Category: Tail Feathers
First priming session was completely unsatisfactory.
Therefore i ordered EkoStrip From Stewart Systems and stripped all the primer (Ekoprime from Stewart System as well).
After doing that i etched and scuffed all the parts again and applied again the EkoPrime. The product itself is good, but my painting skills are not so good.
At the end the result has been satisfactory.


 
Jul 30, 2019     7-5 step 1-5 RUDDER final dril shear clip / Stiffenersl - (1 hour) Category: Tail Feathers
final drill #30 all holes in common with spar
 
Jul 30, 2019     7-6 step 3 RUDDER debur skins, remove plastic - (1 hour) Category: Tail Feathers
debur skins, remove plastic.
 
Jul 30, 2019     7-6 step 1-2 RUDDER complete structur with top and bottom rib - (1 hour)       Category: Tail Feathers
assembly R1003, R1004 with R-1002 spar.
match drill common holes with #30 drill.


 
Jul 28, 2019     7-5 step 1-4 RUDDER assembly stiffener and matchdrill - (2.5 hours) Category: Tail Feathers
assembly R1015A-G left and right and shear clip R1010A-G to the spar R1002.
matchdrill, disassembly and deburr all edges and holes
 
Jul 28, 2019     7-4 step 2-6 RUDDER horn & bottom rib assembly - (2 hours) Category: Tail Feathers
countersunk R1005, deburred all edges, assembled bottom rib assembly, match drilled and deburred
Countersunk striker plates 1/8"" holes and marked for reference.
First countersking on R1005 resulted in a mistake on a countersunk hole drilled too deep. Part replaced with new component.
 
Jul 27, 2019     7-4 step 1 RUDDER Ribs assembly matchdrill deburr - (1 hour) Category: Tail Feathers
R-1003A&B, R1004A&B top and bottom rib assembly, matchdrill and deburr
 
Jul 07, 2019     6-4 step 5 VS prime VS parts (first attempt) - (4 hours) Category: Tail Feathers
clean with ekoclean, acid etch with Ekoetch, prime with Ekopoxy all the VS components
Work done with Laura and Riccardo's help.
 
Jun 30, 2019     7-6 step 1-2 RUDDER complete structur with top and bottom rib - (1 hour) Category: Tail Feathers
Assembled R1003, R1004 with R-1002 spar.
match drill common holes with #30 drill.
 
Jun 25, 2019     7-3 step 1 RUDDER R1015 stiffener fabrication - (3 hours) Category: Tail Feathers
separate R1015 stiffeners, deburr all edges
 
Jun 25, 2019     7-2 step 1-3 RUDDER rib separation, R1010 shear clip part sepa - (2 hours) Category: Tail Feathers
separation of top R-1003A&B, R-1004A&B, and R-1010 shear clips
debur all edges
 
Jun 24, 2019     6-4 step 1-4 VS front spar doubler, rudder stop preparation - (2 hours) Category: Tail Feathers
VS1015 and VS1002 assembly, final drill, deburr. dimple.
Fabricate rudder stops R1007A&B, matchdrill
 
Jun 22, 2019     6-3 step 6-11 VS dimple, countersink, deburr, - (8 hours) Category: Tail Feathers
dimpled holes in VS-1001, all ribs side flanges, countersunk deeper 0007"" (refer to manual Section V) in order to accomodate skin, mark rudder hinges, final drilled VS-1010, VS1011, VS1012. deburred all holes
AVOIDED DIMPLING AND COUNTERSINKING OF FAIRING HOLES MARKED IN PREVIOUS STEP.
GOTCHA: spar hole corresponding to last hole on skin has been countersunk by mistake in step 8.
Disassembled all parts and mark all the parts
Deburred all the parts
Dimpled flange holes Vs-1003 abouve the machine countersunk holes

Final drilled #12 all hinge single holes
 
Jun 20, 2019     6-3 step 3-5 VS assemble skin, matchdrill mark parts - (5 hours) Category: Tail Feathers
assemble VS-1001 skin, matchdrill remove skin and deburr all holes
CAREFUL ON NOSE RIBS. If necessary trim the nose ribs to avoid dents in skin
 
Jun 06, 2019     6-2 step 6 VS machine countersink rear spar - (1 hour) Category: Tail Feathers
machine countersink VS-1008 rear spar doubler on all the #30 holes on forward side of the spar doubler BELOW the Upper Attach bolt Holes
 
Jun 02, 2019     6-3 step 2 VS pre-assemble and matchdrill - (2 hours) Category: Tail Feathers
pre-assemble with cleco all the structure and final drill Vertical Stabilizer structure using #30 dril

Prepare nose ribs trimming the corner as indicated in the horizontal stabilizer section to prevent dents in the skin during final assembly
 
Jun 01, 2019     6-3 step 1 VS deburr all components and check straight - (2 hours) Category: Tail Feathers
deburr all ribs edges, check alignement
 
May 30, 2019     6-2 step 4 - 5 VS assemple rear spar and match drill - (1.5 hours)       Category: Tail Feathers
deburring all component, assemble all the parts including VS-1008 Spar Doubler and match drill with #30 drill all hinge brackets, hinge doubler and all the spar doubler and spart caps 1/8"" holes disassemble and deburr all parts

Match drill the upper attach bolto holes on rear spar, rear spar doubler into the Left and Right Spar caps with a 3/16"" drill

DONT FINAL DRILL holes #12 as this is done when VS is fitted to the tailcone


 
May 29, 2019     6-2 step 2 - 3 VS nest flanges and match drill - (3 hours) Category: Tail Feathers
nest VS1014 L&R into VS1003 and match drill with 1/8"" drill (ignore the 3/16"" upper attach bolto holes) from Spar to Caps.
clecoed VS-1010 and VS-1011 bottom and middle rudder hinges
drill flange holese of VS-1003 and VS-1014L and R spar caps with #40 drill
disassemble and deburring edges and all holes
 


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