Jan 11, 2024     Rudder and Brake Pedals - (2.5 hours)       Category: Controls

My friend Paul and I readjusted the rudder and brake pedals from the mid point to another hole more aft as the current foot to pedal distance was too long.

  Aug 06, 2022     Aileron Actuation - (1.0 hour)       Category: Controls

After struggling with trying to figure out why my right aileron was not reaching the proper throw, I discovered the wing rack I was using (previously for my RV-7) did not allow one of the bell cranks to reach full travel. A slight readjustment of how the wing sits on the rack and the problem was solved. Also, what appeared to be an inference of the bell crank/servo pushrod with the mounting bracket disappeared and hopefully will not come back to haunt me.

  Jul 18, 2022     Aileron Actuation - (3.0 hours)       Category: Controls

The left and right ailerons were placed their neutral position and verified with the W-00026 and W-00030 alignment tools. The nuts and bolts of the wing portion of the aileron control system were then torqued and torque striped to ensure any rotation would be visible. The left wing aileron rod end bearing required no adjustment, while the right wing aileron rod end bearing required just 1/2 turn to bring it into alignment.

  Jul 17, 2022     Aileron Actuation - (1.0 hour)       Category: Controls

The bell crank to aileron control push rods had their locknuts and rod end bearings fitted to 25 1/4 inches and clocked to the 90 degree position. They were then temporarily installed in place in the wings.

  Jul 15, 2022     Aileron Actuation - (2.0 hours)       Category: Controls

When I drilled the rivet holes on the left and right aileron pushrods, I wasn't pleased with the results. The holes were not perfectly matched and I thought the long rivets were going to be difficult, if not almost impossible to perfectly set. So, I ordered two new ones, but due to supply chain problems I was told it would take three months before they would arrive. That was okay, however it's been three months and I just received a letter from Van's stating they were offering a different tube that could be used once modified. I opted to go another route using my existing bell crank to aileron pushrods, mainly due to a drawing depicting an alternate method of installation using welding that was included in the letter - thank you Van's. That method worked beautifully thanks to my friend Keith Phillips who welded them for me. Additionally, we slightly enlarged and tapped the rivet holes, inserted a steel screw thru each, and pounded the ends flat before also welding them in place. Of course this was in addition to welding the fitting to the pushrod. The welded area of pushrods were primed since the original powder coat had to be removed. It should be noted, the new Van's replacements aren't powder coated either, due to supply chain issues.

  Jul 08, 2022     Parts Assembly - (1.0 hour)       Category: Controls

The left and right control sticks were secured to the control stick bases and the connecting aileron control rod was also secured.

  Jul 07, 2022     Control Sticks - (.5 hour)       Category: Controls

The left and right control sticks were temporarily placed in the control stick bases and the distance between the sticks, at the top and bottom, were measured. Both measurements were exactly 20 5/8". The specification called for 20 5/8". Done!!!:-)

  Jul 03, 2022     Aileron Actuation - (1.0 hour)       Category: Controls

The control bases were installed in the actuation control rod. Also, I checked the travel of both of the CS-00006 Control Columns Stick Bases with a digital level. Both were found to be nearly identical and well within the limits identified both in the forward and aft positions, i.e.,14�nd 24�n both sides. I did find a small amount of rust on the inside of the stick bases and sticks. The rust was removed with scotch bright, cleaned and coated with a small amount of wheel bearing grease. (The price one pays for living near the beach in Florida.) Note to self: All of the nuts on the stick bases and control link still need to be tightened.

  Jun 26, 2022     Control Sticks - (1.0 hour)       Category: Controls

After preparing the right control stick for drilling thru to the right control stick base, I drilled the 4 holes per the plans, section 36 pages 10 & 11. I also final drilled the control stick base lugs. As with the left side, the right side alignment is within 0.4 degrees of perfect at this point. Again, we'll see how it ends up once everything is bolted in place.

  Jun 25, 2022     Control Sticks - (1.0 hour)       Category: Controls

After preparing the left control stick for drilling thru to the left control stick base, I drilled the 4 holes per the plans, section 36 pages 10 & 11. I also final drilled the control stick base lugs. The alignment is within 0.4 degrees of perfect at this point. We'll see how it ends up once everything is bolted in place.

  Jun 20, 2022     Control Sticks - (.5 hour) Category: Controls

I unpacked the control sticks/grips and the control stick bases. Since I ordered the control sticks with the Tosten grips pre-installed, the 1/4 inch access hole was predrilled. I then clamped the left stick on the workbench, read the inclination (.04 degrees) and matched the base angle to the stick angle.

  Jun 14, 2022     Flap Control Assembly - (2.5 hours)       Category: Controls

The top flange of the aft flap motor channel was riveted in place. This was followed by riveting the flap motor brackets in place followed by the lower flange of the aft flap motor channel. With this work done, the flap motor was installed in the brackets, safety wired as called out in the plans and functionally tested for proper movement - which was passed with flying colors. Thanks again to Dean who assisted in the installation. The extra hands made this much easier than if I had done it solo.

  May 22, 2022     Rudder and Brake Pedalsr - (1.0 hour)       Category: Controls

Installed the rudder cable guide blocks on both sides of the center tunnel. Also installed cotter pins on the rudder pedal portion of the cable links (fwd). The aft cotter pins on the cable links will be installed after final adjustment of the pedals.

  May 21, 2022     Rudder and Brake Pedals - (1.0 hour)       Category: Controls

Installed the PIC JDAir, Brake Pedal extensions. I highly recommend them & the company is first class. (I do not work for them:-). I also installed, temporarily at least, the cable links to the inboard rudder pedals.

  May 20, 2022     Rudder Control Parts - (3.5 hours)       Category: Controls

After nearly 4 hours and 4 great and helpful friends led by Jeff and Dean, the polyethylene sleeves that protect the spar and rudder cables from rubbing against each other are done!! Don't let this simple task fool you. These 4 cushioned clamps and hardware are extremely difficult to access and get your hands and tools on. Obviously not impossible but hey, they are a little beyond difficult!!!! Anyway, I'll stop complaining and just move on. I'm sure there are more things like this ahead:-)

  May 19, 2022     Rudder Control Parts - (1.0 hour) Category: Controls

I separated the rudder control links, smoothed the edges and removed the rust. I then applied a coat of Rust O'leum Rust Reformer to ensure that any specs of remaining rust are encapsulated. They'll be primed tomorrow.

  May 18, 2022     Rudder and Brake Pedals - (3.0 hours)       Category: Controls

The center rudder/brake assembly bearing block was cut in half. The brake pedal assembly ends have been sanded clean of powder coating, deburred and greased. The end bearing blocks were attached to the brake assembly then the entire system was installed in the forward fuselage as called for in the plans. The top center bearing block was placed between the assembly and the fuselage bracket. The bolts, washers and nuts were put in place, but at this point, only the center bearing block and the forward right bolts were secured. Something to do tomorrow:-) The brake reservoir was cleaned with acetone and properly masked then primer was applied.

  May 17, 2022     Rudder and Brake Pedals - (2.0 hours)       Category: Controls

Completed the installation of the right brake hydraulic fittings on the master cylinders and their installation on the brake assembly. All three of the bearing blocks were drilled to #12 and then final drilled to #10. Drilling the center F-6115 Rudder Pedal Bearing Block to the F-14104 Support Angle correctly was a bit of a challenge on the QB fuselage since the support angle was already installed and fuselage has been rotated right side down and at this point it was more of a hassle to rotate it upright. Lots of tape and clamps were necessary, but doable.

  May 16, 2022     Rudder and Brake Pedals - (4.0 hours)       Category: Controls

Today was spent attaching the left and right rudder pedals to the CS-00018-L & -R Left and Right Brake Pedal Assemblies. I also attached the right side master brake cylinders to the right side brake pedals.

  May 15, 2022     Roll Servo Installation - (2.0 hours)       Category: Controls

Major decision point. I decided to not use the Dynon supplied over center protection device. I'll have to rely on the RV physical aileron stops. With that decision made the installation was straight forward. Physically, the roll servo is installed. The molex connector is next and when the back ordered aileron push rods comes in I'll be able to set up the aileron actuation system. So for now OP-57 can be set aside.

  May 14, 2022     Roll Servo Installation - (2.0 hours)       Category: Controls

I began the roll servo installation by crimping the female molex connector pins on the seven or so wires coming out of the servo. t then took the actuator arm off the servo shaft to install the over center lock protector. Try as I might I could not get this to fit on the already installed brackets. There was no way this would work without major modification. Even with the additional washers the servo could not be lowered to the attach points on the bracket and I was also missing the additional bracket that gets installed to the wing spar bracket and servo. I gave up for the day. But wait, that evening it came to me that there was one place I hadn't checked. Sure enough, it was there. Now I can sleep tonight (maybe). TMI, sorry. (Sadly, a part will always be found in the last place you look - you can quote me on that bit of wisdom.

  May 12, 2022     Aileron Actuation - (3.0 hours)       Category: Controls

A new day. I decided I'll have to remove such of the paint from inside the assemblies. The rust must have been more intrusive than I originally thought. So the inside of the parts were polished, without removing too much material (thousandths only) and then well greased. Two young, great guys (Ethan and Brendon) I helped at Atlantic high school came by and volunteered to help. So I figured I might as well put them work. We (they) struggled with the parts because I didn't want to remove more material. They really worked up a sweat working on it, but we got it done. After they left, I bolted the parts together and brush painted the outside of the collars as it was too risky to spray anything near my RV-7A. They look okay considering no one will likely see these parts. I also think the grease on the inside will provided better corrosion protection than the paint.

  May 11, 2022     Aileron Actuation - (2.0 hours) Category: Controls

Began installation the aileron actuation system by 'trying' to fit the two halves of the torque tube subassemblies thru the spar web and then fitting them together before installing them into the end bearings. No luck! The small amount of paint that was used on the inside and outside of the tubes and fittings prevented the parts from fitting together. Just lightly polishing the parts didn't solve the problem and neither did greasing everything. Time to rethink this:-(

  May 10, 2022     Aileron Actuation - (1.0 hour)       Category: Controls

Completed fitting and drilling the torque tube system. Parts for the left and right ailerons are ready for installation in the wings. Shown is the right system aligned and ready for drilling.

  May 09, 2022     Aileron Actuation - (2.0 hours)       Category: Controls

The torque tube collars were primed over the rust reformer after properly preparing the surface. The left and right CS-00009 torque tube assemblies and the WD-1014 subassemblies had the pushrod ends riveted in place. After the primer dried, the left torque tube collar was inserted and bolted to the forward torque tube assembly. The entire left assembly was then inserted into the WD-1014, the proper length was mapped out and verified then the collar was matched drilled to the WD-1014. I had to stop at this point due to running out of sharp #12 drill bits. New ones will arrive this evening. Shown is the left side assembly.

  May 08, 2022     Aileron Actuation - (3.0 hours)       Category: Controls

With all the aileron actuation parts now drilled, I marked everything then took it all apart to debur the holes. I then took the new abrasive pads and polished the inside of all the tubes to remove the corrosion. After extensively cleaning everything with acetone, I masked the parts and painted the interior of the tubes with the rust reformer. After they were dry to the touch I clecoed the pushrod ends in place using the markings I made earlier. Now I need to wait about 24 hours to let the rust reformer dry before doing anything else.

  May 06, 2022     Aileron Actuation - (2.0 hours) Category: Controls

Moving on to the torque tube assembly and collar. Based on my experience with bell cranks I discovered corrosion inside these parts. This kit was originally purchased in 2013, so these steel parts are 9 years old and corrosion wouldn't be uncommon. I polished the parts enough to drill most of the required holes and call it a day. Next stop is to the Aviation Aisle at Lowe's, where I purchased some abrasive pads and Rust'oleum Rust Reformer.

  May 05, 2022     Aileron Actuation - (2.5 hours)       Category: Controls

I worked on both aileron bell cranks. The nut plates were installed on both, the bushing size was checked and rechecked. However, both the AN4 bolts fit too tightly inside the bushings and the bushings also fit too tightly inside the bell crank and all the measurements were right on. Lots of polishing helped the fit, until I installed them in the plane and torqued the bolts. Then it was too tight again. My friend Dean came by and we determined there was corrosion inside the bell crank. More polishing ensued and with the help of Boelube the bell cranks fit fine and freely moved.

  May 04, 2022     Aileron Actuation - (2.0 hours) Category: Controls

I started fabricating the bell crank to aileron pushrod. Confession time: After drilling the holes I found that the match drilling operation I did - did not, match that is. I definitely need to read the instructions a little closer and/or build a jig or two to stabilize the drilling operation for those holes that accept the -11 rivets. Anyway, I decided to reorder the parts to build these two pushrods. All the parts were inexpensive, but the powder coated pushrod is on backorder - for 3 to 4 months. Oh well, I need to change my schedule. Suggestion: Closely RTFI.

  Jan 14, 2022     Empennage Assembly - (1.0 hour)       Category: Controls

The left, center and right baggage bulkheads were temporarily installed for a check fit. I found no flanging will be necessary, however I think some of the tabs on the upper half of the parts need to be slightly rounded to mold to the aft skin (I don't believe flanging would fix that.) I also installed the aft pitch torque tube on the bell crank to minimize the work necessary once the forward and aft fuselage assemblies are 'mated'.

  Jan 13, 2022     Pitch Servo - (3.0 hours)       Category: Controls

I completed installing the Molex pins for the pitch servo motor wires and inserted them into the newly labeled connector. Once that was complete the servo was temporarily placed on its bracket so I could see if the supplied "limit stop" bracket would fit. It didn't, but Van's had two holes in the bracket so I enlarged them to #29. It did the trick. The limiting stop is in place. Then I bolted the servo in place followed by the pitch servo pushrod assembly. I thought both bolt shoulders protruded a little too much, preventing the the stop nut from locking tight, so I added another washer. There's still over 3 threads showing so things are good.

  Jan 11, 2022     Pitch Servo - (2.0 hours)       Category: Controls

Probably a little out of sequence, but for easier access I attached the mid pitch torque tube to the bell crank, then installed the bell crank bracket (and the attached assembly) into the empennage. This means when I attach the empennage to the fuselage I'll have to deal with the mid pitch torque tube hanging out. That doesn't appear to be a problem, but time will tell. Next is to finish attaching the remaining parts into the empennage. Again, the whole purpose of doing it this way is for easier installation access.

  Jan 09, 2022     Aileron and Elevator Torque Tubes - (3.0 hours)       Category: Controls

With all the appropriate parts primed, inside and out, it's was time to rivet the rod ends to the torque tubes. All 5 of the tubes were pop riveted, using cherrymax rivets, with no issues - except the first rivet. Let me explain in terms of a helpful hint. Evidently the pop rivet gun need adjusting to handle the cherrymax rivets. I didn't know this. If you take off the front round cover it will expose a spring load jaw assembly of some type. I found that if you take the nut and adjust it about a 1/4 inch or so forward from the aft end it will allow the jaws to release the cherrymax nail (stem). If you have the nut full aft, the rivet won't set and if by chance it does, the stem won't release. I suspect everyone in the Van's world, except me, knew this. Thus, I thought I would pass this along to any rookies who might be reading this. Once these were complete I installed the rod end bearings, carefully adhering to the length and depth requirements. No additional problems were encountered.

  Jan 08, 2022     Pitch Torque Tubes - (2.0 hours)       Category: Controls

All three torque tubes were done in the same manner as the aileron torque tubes in the previous entry. The pitch torque tubes are the two small ones and the large tube on the other end.

  Jan 08, 2022     Aileron Parts Fabrication - (2.0 hours)       Category: Controls

The two aileron torque tubes were each drilled to #40, then each rod end was inserted into the tube and both were drilled to a #30 size. The rod end parts were identified so they could be matched up, hole for hole. They were then cleaned (using acetone) and primed inside and out. They're currently drying. In the pictures below (before and after priming), the aileron torque tubes are the middle two tubes that are the same length. Hint: Matching up the rod ends and tubes then marking them with a magic marker didn't work well with my SEM self etching primer as the solvents in the primer dissolved some of the markings. It's easy to realign the parts though so don't panic.

  Jan 07, 2022     Aileron Parts Fabrication - (.5 hour) Category: Controls

I cut the two aileron torque tubes to proper length and deburred the ends. I also gathered the rod end parts in prep for drilling.

  Jan 07, 2022     Flap Control Fabrication - (1.0 hour)       Category: Controls

Dimpled the flap motor channel for the 20 rivets and 10 plates nuts that are now installed. Also, flush countersunk the four rivet holes for the plate nuts in the baggage splice and countersunk the two holes for the flush rivets to be installed later.

  Jan 06, 2022     Pitch Servo - (1.5 hours)       Category: Controls

Drilled the #30 holes in the forward and mid pitch tubes and rod end bearings. Deburred and marked them for later assembly.

  Jan 05, 2022     Pitch Torque Tubes - (2.5 hours)       Category: Controls

Competed the servo pushrods by attaching the rod ends and torquing the lock nuts. Onto the pitch pushrods. Deburred the ends and began drilling the #40 holes in all three of the pitch control tubes and deburred each of the #40 holes. Attached the bearing ends to the the rear pitch tube and drilled the #30 holes in each end. Deburred and marked the ends to reattach in the proper position.

  Jan 04, 2022     Pitch Servo - (3.0 hours)       Category: Controls

Busy day. Cut the pitch servo push rod tubes to the proper length then tapped them with a 10-28 tap. Very time consuming, but rewarding as all four tapped ends fit perfectly. They are currently drying from the primer I sprayed on them. Then it was onto the Bellcrank. With all the parts drilled and primed I riveted the Bellcrank together and installed it on the angles (F-1037A) I had cut some time ago. The assembly was then placed on the bellcrank mount, properly torqued and set aside to await later installation.

  Jan 03, 2022     Pitch Servo - (4.0 hours)       Category: Controls

I final drilled the appropriate holes in all the Bellcrank assembly parts then they were all primed in preparation for riveting. The pitch servo bracket was modified and a lightening hole was made although it wasn't the full 1 1/4 hole. I happen to have a very nice set of expensive hole saws that went up to 3/4 of an inch so I decided to stop there and not ruin a perfectly good part:-) I final drilled the bell crank angles holes to #12. Finally, I countersunk the 16 #40 holes for the plate nuts on the Bellcrank mount and squeezed the rivets to install the plate nuts.