Project: RickWeiss   -  
            Listing for Category : empennage
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Builder Name:Rick Weiss   -  
Project:   Vans - RV-14A   -   VIEW REPORTS
Total Hours:2059
Start/Last Date:Jul 21, 2020 - No Finish Date
 
Friendly URL: https://eaabuilderslog.org?s=RickWeiss

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Jan 16, 2022     Baggage Area Bulkheads - (.5 hour) Category: Empennage
After removing the three baggage bulkhead pieces I determined rounding of the flanges will not improve the fit. I did try to round one and all I could possibly do is ruin the fit that exists.
 
Oct 11, 2021     Empennage Assembly - (1.0 hour)       Category: Empennage
Completed riveting the top skin to the empennage frame. This completes Section 10 - Empennage. Yea!!! I spent the next few hours breaking down one of the shipping containers into useful pieces, cleaning the hangar and rearranging the work area to start on another section of the build.


 
Oct 10, 2021     Empennage Assembly - (3.5 hours)       Category: Empennage
Completed riveting the top right skin to the empennage frame. Began riveting the top skin to the frame and broke for dinner and rest at about 95% complete. This wouldn't have been possible without the outstanding support of my buddy Dean Howard, the 'best bucker' around - seriously!


 
Oct 09, 2021     Empennage Assembly - (3.0 hours)       Category: Empennage
Completed riveting the left top skin to the empennage frame. Began riveting the right top skin, about 30% complete. Completed riveting the F-14131 Upper Aft Fuse Rib, F-01475A Skin Doubler and F-01486F J-Stiffener to the F-01475 Top Skin.


 
Oct 08, 2021     Empennage Assembly - (1.5 hours)       Category: Empennage
Installed the 4 nut plates that, per the instructions, should be installed later. As discussed earlier, these are easy to do now, instead of later and no clear logic (other than the instructions:-), against doing so. Began riveting the upper left skin on, 90% complete (seriously) and 10% to go.


 
Oct 07, 2021     Empennage Assembly - (4.0 hours)       Category: Empennage
Dean and I completed riveting the aft deck and all the angles and the bulkhead. I applied silicone to the wires going thru the aft bulkhead to protect them from any sharp edges in the hole they go thru. I connected the C409P connector in its slot on the aft deck, and ran the wires and phone cable thru their hole in the aft deck. A snap bushing was cut and inserted into the hole to protect the wires. The vertical stabilizer was temporarily secured in place and the 2 #12 holes were drilled perpendicular to the VS stab spar. The VS was removed and the holes deburred. The left skin was clecoed to the empennage and after much thought and discussion with my friend Dean, I intend to remove it and fasten the 4 nut plates to the longerons as well as the 2 top of the skin nut plates. It's much easier and a cleaner installation to do it at this point than it will be in section 12 of the instructions. I know it's a deviation from the usual great instructions from Van's, so we'll see how it goes. The entire bottom of the empennage was vacuumed and cleaned to protect the innocent.


 
Oct 06, 2021     Empennage Assembly - (5.0 hours)       Category: Empennage
After a lot of research I enlarged (only slightly) the wire hole in the aft bulkhead thus allowing all the wires for the tail strobe to be pulled thru. I also enlarged the matching hole in the vertical stabilizer. With this done I aligned the wires in the Empennage and secured all the tie wraps. With the help of Dean, I began riveting the F-01414 Aft Deck, F-01412C Deck Angle, F-01411E Deck Doubler, F-01411D Horizontal Stab Attach Bar Support Angle and F-01409 Frame to the Aft Fuselage. It's not as easy as I thought it would be. Fortunately, we have only a few more rivets to go.


 
Oct 05, 2021     Empennage Assembly - (2.0 hours)       Category: Empennage
This morning I clecoed the F-01414 Aft Deck, F-01412C Deck Angle, F-01411E Deck Doubler, F-01411D Horizontal Stab Attach Bar Support Angle and F-01409 Frame to the Aft Fuselage. I then match-drilled the #30 holes in the F-01411C Attach Bars to the F-01411D Horizontal Stab Attach Bar Support Angle, then match-Drilled #30 and #40 the holes in the F-01412 Bulkhead into the F-01412C Deck Angle. The gaps visible in the pictures will disappear when everything is fully clecoed (and tweaked). Things are ready to rivet, but I have to figure out the wiring harness routing and tighten them up while access to them is easy.


 
Oct 04, 2021     Empennage Assembly - (2.5 hours)       Category: Empennage
Finished dimpling the top side skins and top skin. All aft deck parts deburred, the faceted edges on F-01409 Frame were rounded and the frame dimpled. Dimpled the F-01414 Aft Deck, primed the F-01412C Deck Angle and F-01411D Horizontal Stab Attach Bar. Dimpled the holes in the upper flange of the F-14131 Upper Aft Fuse Rib, all the holes in the F-01475A Skin Doubler and dimpled all holes in the F-01486F J-Stiffener.


 
Oct 03, 2021     Empennage Assembly - (4.5 hours)       Category: Empennage
Deburred all of the top skins and dimpled the number 40 holes on the top side skins.


 
Oct 02, 2021     Empennage Assembly - (3.0 hours)       Category: Empennage
Fabricated two spacers to assist in clamping the static ports to the skin. Scuffed the mating surfaces of the static ports and skin. JB Welded the static ports to the skin, clamped them in place and now I'm letting them setup for an hour or two. Now, with the static ports secure, I installed the tee on the left side and screwed it onto the bulkhead. Then the static system tubing was fitted and secured to the F-01407 Bulkhead. The left side static tubing was run forward along the left F-01429 rib and the remaining tubing was coiled up for later. CAUTION: The WH-00057 wire was pinched between the F-01408 bulkhead and it's mid fuselage J stiffener. It look a lot of work to free it up. This happened during the riveting of the left side skin and the bulkhead. It's difficult to see when riveting, so just a word of caution when riveting. It was compressed, but not cut. Will see how it works later during an end to end test.


 
Oct 01, 2021     Empennage Assembly - (1.0 hour)       Category: Empennage
Completed installing the left rudder cable guide. WARNING: Per Van, using a different rivet than called out was okay, as it's a low stress area. I also used a -5 length which made a lot more sense than the -4 that was called out. Be sure to think about that when you get to your guide.

I'm using the Safe-Air pitot static installation. I used it on my-7A and it's excellent. Passes the static system test every two years with no errors or leakage. I drilled the static ports out to the required .250 inch. I've got over 50 clamps but none that could clamp the static port to the skin. A trip to Harbor Freight fixed that. Got a free flashlight too, wahoo!


 
Sep 29, 2021     Empennage Assembly - (4.0 hours)       Category: Empennage
Installed the empennage's aft right side skin plate nuts including those on the inspection cover opening. Then I riveted the F-01473A angle to the right side skin, ran the rudder cables through the empennage and installed the right side cable guides and tried to install the left side guides, but two of the AACQ4-4 rivets on the left side cable guide pulled through the washers and the mandrel broke before it came out of the rivet. I'll have to drill them out and retry again with two remaining rivets that I have. Tension mounts:-) The rudder cables were stowed behind the F-1406B Bulkhead.


 
Sep 28, 2021     Empennage Assembly - (7.0 hours)       Category: Empennage
The right skin was prepped with cleocs in every few holes. We turned the fuselage bottom up with me on the outside and Dean, who generously volunteered for inside bucking duty. Most areas were easy to get too, but there were a few tight places. The bottom the side skin was a little difficult as care was take on the curved surfaces. The aft end, although tight was completed with "relative" ease. While not yet complete, it's starting to look like an airplane part.


 
Sep 27, 2021     Empennage Assembly - (2.5 hours)       Category: Empennage
Odds and ends day. Completed the aft inspection cover dimpling. WARNING, my inspection plates weren't labelled Left or Right and there is a fitment difference. Be sure you check the fit before dimpling. Just saying:-) Anyway, after some adjustment all is well. The inspection cover nut plates were installed and the top two #27 holes were machine countersunk. The F-01473A angle was riveted in place. The right skin was 'broke' to fit the bottom and installed on the frame. I then fed all the J stiffeners and the longhorn on the back side of the skin and clecoed them in place. Lots more cloches to go but things are looking good. I also countersunk and fit checked the cable guides.


 
Sep 26, 2021     Empennage Assembly - (1.0 hour)       Category: Empennage
Completed riveting the left skin to the empennage frame and lower skin. Installed the 6 nut plates onto the aft left skin and longeron.


 
Sep 25, 2021     Empennage Assembly - (2.5 hours)       Category: Empennage
Dean and I finished riveting the lower row of aft side rivets on the left skin. We then riveted the aft portion of the bottom skin. My concern over the mating of the left skin to the aft bottom skin was put to rest as the left skin conformed nicely to curvature of the aft bottom skin. Arranging the the empennage to be able to rivet the bottom portion was interesting. The picture shows the awkwardness, but the most efficient way to get the job done. I didn't want to back rivet this for fear of denting the skin with the steel plate.


 
Sep 24, 2021     Empennage Assembly - (5.5 hours)       Category: Empennage
With the help of Dean Howard we riveted about 80% of the empennage's left side skin. Lots of tough ares to get at, but those areas are now done. Progress!


 
Sep 22, 2021     Empennage Assembly - (3.0 hours)       Category: Empennage
The aft skin pilot hole was riveted as well as the aft bulkhead to the aft skin. I tried back riveting but that didn't work out well as I couldn't get the rivet set perpendicular to the rivet. Fortunately my friend Jeff Rule stopped by and we riveted it the old fashioned way, but it wasn't easy. Also, the rivets that were called out were too short so we switched to a slightly longer rivet - problem solved. The left side skin was clecoed from the inside in the hope I can back rivet the side skin in place. Time will tell. I also installed the WH-000057 wiring fix kit which consisted of an extension of two wires. The C1036 and C1037 wires were crimped then heat shrink tubing was placed over the joint.


 
Sep 21, 2021     Empennage Assembly - (2.0 hours)       Category: Empennage
Began installation of the ELT antenna cable, the UAT antenna cable and the FlyLeds tail strobe power/control line. The appropriate plastic bushings were slit to allow installation of the end fittings. I say began installing because before I tighten all of the tie wraps in place I want to be sure no more lines are necessary. Also, by leaving them "loose" it allows for cable movement to allow riveting the side skins.


 
Sep 20, 2021     Empennage Assembly - (3.0 hours)       Category: Empennage
I decided to use the internal rudder stop from Flyboy Accessories, an outstanding company to do business with. I used this on my RV-7A and they're great. That being said I had dimpled the 4 holes for the external rudder stop and 'plugged' them with the appropriate rivets. You may want to consider this as getting a rivet set onto the rivets of the external stop is very tricky if not near impossible to do. With that job complete I began the task of laying out the aft fuselage wiring. This started with installing plastic bushings in many holes of the ribs and bulkheads. It appears I will have to slit 3 of the bushings in order to pass the connectors thru - no big deal. I also installed the phone line for the ELT, again, this will require a slit in each of the two bell crank ribs and some trimming of the corners to fit thru the bushings. Be advised a lot of clecos will be removed and replaced as the wires are strung thru to the back of the aft fuselage along the channel of the J stiffeners. While I installed some tie wraps, there are many others left to do and redo. What appears to be an easy task is just a little more complex when you get into it.


 
Sep 19, 2021     Empennage Assembly - (1.5 hours)       Category: Empennage
Began assembly of the aft fuselage side panels.


 
Sep 18, 2021     Empennage Assembly - (2.0 hours)       Category: Empennage
Service Bulletin 18-09-17 has been completed. All the required doublers, clips and spacers are in place. Riveting of the BellCrank Ribs and the difficult to reach bulkhead rivets are now done. The smudges on the doubler, from the rivet gun will be easily removed when the plane is prepared for painting.


 
Sep 17, 2021     Empennage Assembly - (3.0 hours)       Category: Empennage
I decided to back rivet the aft bottom skin to the stiffeners and bulkhead ribs. To do this, I reversed the clecos holding the stiffeners, etc to the bottom skin so it would lie flat (more or less) on the work bench. With this done it just a matter of rivet taping the rivets in place and then ensure they would lie flat on the steel plate. Easy peasy and all the rivets were perfectly set., except that I was unable to rivet the bulkhead ribs because the back rivet set and my offset flat head set would not fit over the rivets due the flange on the top of the ribs. Oh well, back to bucking rivets tomorrow.


 
Sep 16, 2021     Empennage Parts Fabrication       Category: Empennage
Machine countersunk the gazillion #40 holes in the F-01418B-L & -R Longerons so they would fit a dimpled skin. I also cleared the work table to prep for back riveting the aft fuselage bottom skin. A departure from the instructions so we'll see how it goes.


 
Sep 15, 2021     Empennage Assembly - (2.0 hours)       Category: Empennage
Completed the dimpling of all stiffeners for the aft fuselage. Riveted the rear flanges of the Bellcrank rib assembly to the F-014017 Bulkhead. I also riveted the center rivet on the Bellcrank Bulkhead. I then began the process of assembling the aft fuselage by clecoing the aft skin stiffeners, bulkheads, bulkhead ribs, etc to the aft skin. All this was accomplished on the sawhorses recommend in the instructions.


 
Sep 14, 2021     Empennage Parts Fabrication - (2.5 hours)       Category: Empennage
Completed the side skin dimpling of all #40 and #30 holes including those for the rudder stop which are marked for dimpling. The reason for this is because I've chosen to use an internal rudder stop vice the angle bracket. I also completed fabricating the the aft bottom skin, cutting off the extended skins, deburring, filing smooth the edges, drilling the required holes and dimpling the skin. Repair of the dimpling table was finally needed to reinforce the holding frame and strengthen the legs. This table has supported multiple aircraft builds and has really taken a beating, so it earned a small makeover. The C Frame has also done an outstanding job of holding up to the pounding of the dimpler.


 
Sep 13, 2021     Empennage Parts Fabrication - (2.0 hours)       Category: Empennage
Completed dimpling all of the #40 holes in the side skins. The curved portions of the skins were done with a reduced diameter die that I was lucky to find. Even with the reduced diameter die it was difficult to get the 'perfect' dimple. However the good news is that breaking of the skin on the curved portion straightened out nicely and looks much better.


 
Sep 12, 2021     Empennage Parts Fabrication - (1.5 hours) Category: Empennage
Before continuing the dimpling effort I broke the edges on both side skins and the bottom skin. This is one task I don't look forward too. No matter how hard I try, the break comes out looking rippled. I know when the rivets are in place it's straight as can be, but it just looks wrong. Oh well. I continued dimpling the left skin, including the the #27 holes for the flush screws, except the top two. I also did the #27's on the right skin and both F-01486A Stiffeners. I stopped short of finishing the left side skin curved areas. I'll need to reduce the diameter of the dies by about a 1/16 of an inch and maybe taper the edges so the skin doesn't get creased from the dies. Again no pictures at this point.
 
Sep 11, 2021     Empennage Parts Fabrication - (1.5 hours) Category: Empennage
Since my preowned kit is almost 8 years old I decided the blue plastic must totally come off of the parts as I get to them. This time it was the empennage side skins. They're large and the plastic really was stuck on. Almost the entire time was spent removing the plastic. The last few minutes were spent masking off holes that don't get dimpled and beginning the dimpling of the left skin. Not worth taking a photo yet.
 
Sep 10, 2021     Empennage Parts Fabrication - (1.5 hours)       Category: Empennage
I researched the details for installing the SB18-09-17 in an older kit that hasn't been dimpled or riveted. With that done I taped certain holes, to prevent inadvertent dimpling where the doubler will get installed on the lower skin. Then I dimpled the the bottom skin.


 
Sep 09, 2021     Empennage Assembly - (1.0 hour) Category: Empennage
I dimpled the #40 holes in the flange of the F-01486B-R, F-01486C-L & -R, and F-01486E & F J-Stiffeners. Interesting note for those with older kits. It appears the callout in the rev 1 drawing on page 10-13 for a J-stiffener F-01486G does not apply to older kits. The original drawing has a callout for two J-Stiffeners, F-01486 E&F. It took a while to figure this out since there was no 'G' part in my kit or in the parts list. I'll just go with the two stiffeners and call it a day. I dimpled both of them.
 
Sep 08, 2021     Empennage Assembly - (1.5 hours)       Category: Empennage
After being off a while due to heart surgery, it's time to start building again, at least slowly for a while. So I began by dimpling holes in the F-01486B-L J stiffener. I also need to incorporate the SB18-09-17 for the Aft Fuselage Cracks. I separated the F-14147-L&R clips and dimpled the holes in the base of the clips. The stiffener doublers, F-14148B&C were separated. Finally, the F-14148A Skin Doubler was beveled and countersunk. All parts were deburred, scotch brighted and primed.


 
Aug 21, 2021     Empennage Assembly - (2.0 hours)       Category: Empennage
Installed all the nut plates on the F-01406B Bulkhead and almost riveted the F-01429-L & -R Bellcrank Ribs to the F-01406B Bulkhead. The center L & R rivets were just out of reach of my manual rivet squeezer. They'll need to be bucked next time return to the hangar.


 
Aug 17, 2021     Empennage Parts Fabrication - (2.0 hours)       Category: Empennage
With the battery angles primed and now dry, it's time to attach the nut plates and fasten them to the Bellctank Ribs. But first the ribs must be dimpled and now with the dimpling complete the parts were all assembled and appropriately riveted.


 
Aug 14, 2021     Empennage Parts Fabrication - (1.5 hours)       Category: Empennage
Final drilled the @40 holes in the F-1037-B&-C Battery Angles, deburred, countersunk the holes, then final drilled the #12 holes and deburred them. The parts were then scuffed, cleaned and primed in preparation for nut plate installation and attachment to the Bellcrank Ribs.


 
Aug 11, 2021     Empennage Parts Fabrication - (1.0 hour)       Category: Empennage
Completed the F-01407 bulkhead riveting. That piece is done. The F-01408 bulkhead presented some issues. The part did not appear to be the same as in the drawing (rev 2). After a discussion with Van's AWESOME tech support, it was determined the new bulkhead is a -1 rev and the original 2013 is not. The new part was changed due to the aft fuselage cracking issue and the subsequent SB. The new drawing shows the new part, not the bulkhead pieces that came with my 2013 kit. Solution? Use the old drawings for that bulkhead and build on, then install the SB parts as if the plane was already flying with the old parts.


 
Aug 07, 2021     Empennage Parts Fabrication - (1.0 hour)       Category: Empennage
The F-0140 Bulkhead was completed (short of fluting) with installation of the 19 -8 universal head rivets that hold the F-01410C Horizontal Stab Attach Bar, F-01410A and F-01410B Bulkhead Doublers to the F-01410. At 90PSI the pneumatic squeezer just wouldn't cut. (I didn't want to up the pressure too much.) Seems the rivets are a little hard. My son was nearby and after his 15 mile bike ride he stopped by and manually squeezed them. They came out just fine.


 
Jul 31, 2021     Empennage Parts Fabrication - (4.0 hours) Category: Empennage
The fun persists as I continued deburring and preparing parts for assembly. I worked on the F-14115-1 bracket and spent time locating other parts that I haven't seen in a long time. I also separated the F-01429 Bellcrank Ribs and prepped them and the F-01406B Bulkhead for later assembly. While things are going slowly during this phase I hope to pickup the pace over the next month when the aft fuselage starts to look like a real airplane part. Also, I've spent hours researching items to purchase so they're onboard the hangar as the plane starts to come together.
 
Jul 28, 2021     Empennage Parts Fabrication - (3.0 hours) Category: Empennage
Continued the fabrication of the F-01410 Bulkhead. The AN470AD3-3.5 rivets weren't included in the kit and are not available at Aircraft Spruce. I'll be calling Van's later this week. I did manage to to borrow some AN470AD-4's and used them, but as expected a couple of them did not set well and had to be drilled out. One of them had to be replaced with an AN470AD4-4 because the hole got enlarged. No problem and just continued on by deburring and preparing the F-01407-L & -R and F-01408-L-1 bulkheads.
 
Jul 25, 2021     Empennage Parts Fabrication - (1 hour) Category: Empennage
I prepped the F-01410 Bulkhead, drilled the system hole and the 1/4 inch holes the horizontal stab bar. Primed the attach bars and clecoed the assembly together. Then I noticed the rev date on my drawing is 2014 and there is a later version so I may have to go back and adjust things. I'll have to do that for all pages in this section. It's always something.
 
Jul 24, 2021     Empennage Parts Fabrication - (9 hours)       Category: Empennage
Over the past week the F-01412A and F-01412B Bulkheads were prepared, match drilled, dimpled and the tie down bracket drilled, countersunk and primed. With these steps completed the parts were riveted together, but not without stupid issues. A #12 drill broke off in the vertical stab. I noticed I wasn't making any progress drilling, plus I was starting to ruin the hole. Then I took everything apart and saw the end of the bit lodged in the vertical stab. After removing it, I enlarged the hole (so as not to deal with a damaged hole) to accommodate an AN4 bolt and moved on. Also, after riveting the tie down bracket I noticed two adjacent dimpled holes. The instructions clearly indicated to dimple. My bad, I should have checked closer and fixed the issue. Oh well. (I may just order new parts and do this over.) With this mess behind me I moved on to the F-01411A and F-01411B Bulkheads and the attach bars. This went totally smooth and all the rivets were set without issue. I decide to wait until later to flute the lower flange. To end the day I final drilled to 1/4 inch, the F-01410C Horizontal Stab Attach Bars.


 
Jul 16, 2021     Empennage Parts Fabrication - (2.0 hours)       Category: Empennage
After much searching I located and separated the F-01497B Cable Guides. These nylon pieces were unmarked and in a non-descript bag. Also, take note; they are not in the empennage parts list (circa kit 103). I completed fabricating the F-01411D Horizontal Stab Attach Bar Support Angle and primed it. I decided to install the Flyboy accessories internal rudder stop, as I did on my RV-7A. An excellent product and thus no need to fabricate the F-14113-L & -R Rudder Stops. Moving on to the F-01412A and F-01412B Bulkheads, I smoothed the edge surfaces and went to do a test fit on the vertical stab but I found one of the locator holes was 'missing'. After researching it, I found the previous kit owner riveted something that should have had the rivet omitted. Thus, there wasn't any way to cleco the bulkheads to the vert stab. Time to perform a rivet extraction. I also need to round the bulkhead flange corners to allow for a good fit when compressed by the skins.


 
Jul 11, 2021     Empennage Parts Fabrication - (2.0 hours)       Category: Empennage
Completed fabricating F-01418B-L & -R Aft Fuselage Longerons and primed the two F-01411C Horizontal Stabilizer Attachment Bars.


 
Oct 07, 2020     Elevator Construction - (2 hours)       Category: Empennage
After 50 strokes on the Flamemaster Adhesive cartridge (thanks to Paul for doing over half of these strokes and for his assistance in slopping the stuff on the ribs-messy day) , both elevators and the trim tab had the aft foam ribs bonded to the upper and lower skins. The trim tab also had the aft hinge and upper skin riveted to the front spar. All three parts are now weighted down and will cure until Saturday.

(Currently, the system will not allow photos to be uploaded.)


 
Oct 06, 2020     Elevator Construction - (2.0 hours) Category: Empennage
The left, right and trim tab trailing edges were scuffed and cleaned as were the trailing edges. The 3M tape was applied to both sides. The lower side of each trailing edge was placed on their respective lower skin. A cleco was placed at each end to hold the trailing edge in place and the paper covering the adhesive was removed. Cleco's were then placed in each lower skin trailing edge only thru to the trailing edge piece. The parts are now sitting overnight to allow the adhesive to cure.
 
Oct 05, 2020     Elevator Construction - (3 hours)       Category: Empennage
Riveted the left elevator upper and lower skins to the left forward spar. Also, completed all necessary elevator riveting prior to bonding the foam ribs in place on all surfaces.


 
Oct 04, 2020     Elevator Construction - (2.0 hours)       Category: Empennage
Riveted the right upper and lower elevator skins to the forward spar. A number of other components were riveted in place including the MK-319-BS rivets in the counterbalance skins on both the left and right sides.


 
Oct 02, 2020     Elevator Construction - (3.5 hours)       Category: Empennage
The right elevator front spar, end root ribs and gusset were riveted into the structure and rear spar. The left forward spar and end root ribs were riveted to the gusset and shear clip. The reinforcement doubler was riveted into the structure in multiple places. The lower rivets were very difficult to set. The rivets in the left gusset to rear spar and rear spar to root rib were just not agreeable to being riveted at all, flush set or not. To ensure a good, solid fit, I used the LP4-3 blind rivets in their place. The E-905 root rib was riveted to the upper and lower skins. The 3 end rivets, previously left open were now riveted into place.


 
Oct 01, 2020     Elevator Construction - (3.5 hours)       Category: Empennage
The elevator upper and lower ribs were pop riveted together. The left elevator front spar assembly was clecoed in place and the front spar was clecoed to the ribs for rivet installation as were the gusset and shear tab. The manual is correct as reaching in to rivet the rear portions of the ribs together was difficult, but obviously it can be done, with much patience. No elevator skins were injured in this process:-)


 
Sep 30, 2020     Elevator Construction - (3.5 hours)       Category: Empennage
The elevator skins were placed top over bottom and the ribs were clecoed together (not too easy, but doable). Then the left and right skins were clecoed to their respective rear spar and riveted together. This is where the special RV-14 bucking bar comes into play. First, a little practice (6 rivets) on the bottom left skin, then the top right skin. Actually, this was much easier than what was thought. Finally I made the pull rivet assist tool. A big thanks to Paul and Roger. It wouldn't have been as easy without their excellent help.


 
Sep 29, 2020     Reinforcement Doubler Riveting - (1 hour)       Category: Empennage
Riveted the trim access reinforcement doubler and its brace to the left bottom elevator skin. Riveted the brace to the doubler with the single LP-4-3 blind rivet. The doubler's nut plates were also riveted.


 
Sep 28, 2020     Riveting the Ribs - (4.5 hours)       Category: Empennage
Completed riveting both aft spars to the left top skin and bottom right skin. Riveted the ribs to all four elevator skins skins. Riveted the trim reinforcement plate to the left bottom skin.


 
Sep 26, 2020     Assembling the Elevator - (6.0 hours)       Category: Empennage
Completed the riveting of the elevator horns. Riveted the gusset and shear clips to the rear spars. Riveted the E-1008B ribs to the rear spars. Clecoed the spar/rib assembly to the appropriate elevator skins. Began riveting the left skin to the spar and the forward trim tab hinge.


 
Sep 25, 2020     Elevator Frame Riveting - (2.0 hours)       Category: Empennage
Completed the first phase of riveting the counterbalance skins to the outboard ribs. Nearly completed the installation/riveting of the left and right elevator horns.


 
Sep 24, 2020     Elevator Skin Dimpling - (1.5 hours)       Category: Empennage
Completed dimpling the four elevator skins with my college roommate Paul.


 
Sep 23, 2020     Elevator Construction - (4.0 hours)       Category: Empennage
A day for completions - even minor ones, Completed the preparation of the top elevator skins for the bonding of the foam ribs. Completed the countersinking of the trailing edges. Completed the dimpling of one of the elevator skins.


 
Sep 22, 2020     Elevator Construction - (2.0 hours)       Category: Empennage
Completed the first set of riveting of the elevator structure and redid the left and right elevator trailing edges to improve the transition to the elevator fairings..


 
Sep 21, 2020     Elevator Construction - (4.0 hours) Category: Empennage
The left and right elevator's tip ribs, root ribs, and gusset were riveted to each other and/or the forward spar. The 4 hinge reinforcement plates were scuffed, primed and clecoed in place for later riveting.
 
Sep 20, 2020     Elevator Build - (1 hour)       Category: Empennage
Deburred the four hinge reinforcement plates. Assembled the basic structure of the left and right elevators in preparation for riveting the parts together.


 
Sep 19, 2020     Elevator Prep for Foam Ribs - (3 hours)       Category: Empennage
The left and right lower skins scuff area for the foam ribs were located, masked, scuffed and cleaned. The aft spars were also scuffed in the area of the foam ribs.


 
Sep 18, 2020     Pitch Trim Tab - (4.0 hours)       Category: Empennage
The pitch trim foam ribs were laid out precisely where they will be bonded to the lower and upper skins as were the spar and trailing edge. The areas on the skin were marked, taped off then scuffed with 150 grit paper then cleaned with acetone. The top and bottom skins were then dimpled and the trailing edge holes dimpled with the modified #40 dimpled. The spar and pitch trim horn were clecoed in place on the lower skin and subsequently riveted together.


 
Sep 17, 2020     Pitch Trim Tab - (2.0 hours)       Category: Empennage
The pitch trim spar was countersunk for the upper skin. It was also dimpled for both the upper and lower skins. The trailing edge was ever so precisely countersunk per the instructions on the top and bottom sides so the countersinks were perpendicular to to the surface.


 
Sep 16, 2020     Elevator Trim Tab - (2.0 hours)       Category: Empennage
The trim tab skins were deburred and the rear edges received their break toward the inside. The trim tab was completely assembled with the foam ribs taped in place and the trailing edge trimmed to fit. The closeout tabs were dimpled and drilled out to a size #33. The trim tab was disassembled in preparation for countersinking the trailing edge.


 
Sep 15, 2020     Elevator - (2.5 hours)       Category: Empennage
The trim access doubler received the nut plate installation and the trim pushrod was machined countersunk and double flush riveted. The trim tab horns were cut/trimmed, dimpled and of course all parts deburred. The right top skin was also deburred. I also ensured the spars had not deformed during the dimpling process.


 
Sep 14, 2020     Dimpling and Countersinking - (3.5 hours)       Category: Empennage
The forward spar, trim tab hinge spar and aft spar were all countersunk and/or dimpled in accordance with the plans. Many more of the smaller parts were also dimpled such as the trim access reinforcement doubler, and it's brace. As I mentioned yesterday, things break. In this case my microstop's nylon base separated from the metal base. JB Weld to the rescue. I polished the the metal base, then scuffed it and applied epoxy and set it aside for an overnight curing. I continued on with another microstop and finished the task at hand.


 
Sep 10, 2020     Elevator Build - (3 hours)       Category: Empennage
Today was spent final drilling a number of holes, then disassembling the right elevator, marking the appropriate pieces for reassembly, deburring, and dimpling of various external and internal parts. The left elevator, already apart had parts dimpled and all parts (up to this point) now deburred.


 
Sep 09, 2020     Elevator Build - (5.5 hours)       Category: Empennage
I started the day clecoing the top skin and tip ribs to the left and right elevators. Then the trailing edges were fit and trimmed. A time consuming task as there were a significant number of trim fits, sanding and cleco moving to ensure a good fit. Once that was done it was on to temporarily installing a foam trailing rib to get a good fit for drilling the holes for the closeout tab along with attaching the top skin.. The closeout tab bends I did were magnificent as the upper and lower tabs fit perfectly with each other. Unfortunately they sucked at meeting with the the shear clip. An eighth inch gap was there and shouldn't have been. A fix, coordinated with Vans tech staff, had me move the shear clip over to meet the perfect tab. Two new holes were drilled for the shear clip into the spar. No big deal. The gap between the trim tab and elevator looks perfectly fine. Next, both elevator horns were drilled in place. Finally, I disassembled the left elevator so all the parts that hadn't been deburred, could be deburred and the drilled holes cleaned up. Tomorrow, the right elevator will get disassembled.


 
Sep 08, 2020     Elevator Build - (4 hours)       Category: Empennage
Continued building the elevator by fitting the hinge for the trim tab. With the hinge separated, the forward hinge was attached to the spar with the pilot hole.lined up parallel to the skin and the holes drilled thru the spar into the forward hinge. Similarly, the aft portion of the hinge was drilled. Then the excess hinge material was cut, fitted and, of course, the parts deburred. Next the trailing edges. All three were fitted. Next the gusts and shear clips were installed and drilled.


 
Sep 07, 2020     Elevator Construction - (4.0 hours)       Category: Empennage
After the usual cutting, trimming, and deburring almost all of the elevator parts are ready for the initial fit check. The left and right elevators were constructed with the parts required per the drawings. This went well and now the preparation of the trim tab and aft foam ribs can begin to take place. Lots more to do on the elevator before riveting and glueing, but it's coming along nicely.


 
Sep 06, 2020     Elevator - (3.5 hours)       Category: Empennage
The left top and bottom elevator skin closeout tabs were each hand bent to 90 degrees. Be very careful here to identify and mark the bottom of each of the skins before you bend the closeout tabs. The trailing edges of the skins when secured to the workbench should slope upward and this will identify the top of the skins. The closeout tabs will then be bent downwards and that will be the bottom of the skin. The right rear spar was bevel trimmed per the drawing and the trim tab hinge had the fore and aft pieces identified and drilled per the drawing to number 40. The forward left spar had the identified #30 holes enlarged to 5/8 and 3/8 with a step drill bit. Finally, the front spars were deburred and clecoed to their respective skins.


 
Sep 05, 2020     Elevator Trim Tab - (2.0 hours)       Category: Empennage
Fabricated the eight foam trailing edge elevator ribs and three foam trim tab ribs by applying spray adhesive to the face of the foam and placing copies of the trim lines on each of them. I set them aside to dry. While waiting for the adhesive to dry I removed the hatched areas on the close out tabs of the trim skins. I used cutters since the bandsaw wouldn't work in this area. Then I smoothed and deburred all the edges of the skins with the scotch bright wheel. Back to the trailing edge ribs. Now that the adhesive is dry I rough cut them to the trim lines on the bandsaw and then sanded them flush to the trim lines.


 
Sep 04, 2020     Elevator - (3.0 hours) Category: Empennage
Easy day working to separate the shear clips and deburring them. Then onto the tip ribs assembly and counterweight skins, where there were lots of deburring to do and opening up of the #30 and #40 holes. Luckily no fluting was required. I think deburring alone would account for 99% of the 51% rule:-)
 
Sep 03, 2020     Building the Elevator - (3.0 hours)       Category: Empennage
A busy time gathering all the parts then separating the ribs, deburring, and clecoing them together. All went smoothly, but getting everything deburred does take a lot of time to do it properly. All the edge surfaces required a variety of filing, sanding or scotch bright work. Some required all three. Not difficult, but tedious. This picture was taken a rush, but I'll have better ones later.


 
Sep 02, 2020     Vertical Stabilizer and Rudder - (2 hours) Category: Empennage
Since my kit was previously owned and owner built the vertical stab, I thought it prudent to inspect it. It took nearly and hour before I completed the inspection and gave it a thumbs up. The previous owner also started the rudder. He did rivet the stiffeners to the skins. The left one was okay and as noted previously I needed to do a new right rudder. The parts from Van's had arrived so I took them out of the box, inventoried them and began the build. I trimmed the stiffeners and then deburred them. I went to get the new right skin which was still taped to the box. I removed it from the box and started right in removing the tab at the top and trimming 3/32 inch off the top of the flange per the drawings. It went perfectly until I noticed skin looked just like the left one. Long story short, Van's had sent a left skin instead of the right one. I called them and they were great, the new part is already on it's way. The only trouble is they're on the west coast and I'm on the right. It's a long drive so it will be at least a week before I see it. So, I moved all the ruder parts to a storage location and decided to start on the elevator.
 
Aug 31, 2020     HS Complete, less fiberglas tips. - (3.5 hours)       Category: Empennage
The riveting of the HS skins is complete. The geometry of the rear spar and the skins prevented me from using the pneumatic squeezer, but the good old manual squeezer did just fine. A few ibuprofens and this builder will be fine. Next up, the right rudder.


 
Aug 30, 2020     Horizontal Stabilizer - Nearing completion! - (1.5 hours)       Category: Empennage
Squeeze riveted the inspar modified ribs and the end ribs to the rear spar. Pop riveted the remaining ribs to the rear spar. Also, solved the shop air issue. Last time, I left off with no shop air to the pneumatic tools. I found a worn out coupling. Replaced it with one purchased from the aviation aisle at Lowes. The coupler they sell is awesome, push to lock, click to unlock, looks great, easy to use, but as best as I can tell it doesn't cleanly accept varieties of male inserts. Thus when I installed it, I still wasn't getting air past the coupling. I replaced the fancy one with an old fashioned one and it worked fine. I also installed a second air line so I could use the pneumatic cleco tool in conjunction with the pneumatic squeezer. Evidently all male inserts aren't the same. If I could start with a clean sheet, I would use all Lowes parts. That would have solved the problem. Next time:-)


 
Aug 28, 2020     Right Rudder Parts - (2.5 hours)       Category: Empennage
After receiving the new right rudder parts, I've now separated the stiffeners, attach strips, shim, trim horn brace and the bottom rib. They have now been trimmed and deburred.


 
Aug 28, 2020     Rear Spar - (1.5 hours)       Category: Empennage
After clecoing the rear spar on the HS, I removed it so I could remove some tape I inadvertently left on the doubler to prevent aluminum filings from getting between the doubler and web. Then I reattached the rear spar on the HS assembly. The HS is ready for riveting however, I now have a problem with my air supply to the air tools. I believe one of the hose couplers is stuck in the closed position. We'll see.


 
Aug 27, 2020     Completed riveting the HS skin to the ribs and front spar. - (4 hours)       Category: Empennage
Paul and I completed riveting the HS skin to all the ribs, stringers and the front spar. We then placed the rear spar on top the assembly (notch at the bottom) and placed a few checks in it to hold it in place until we resume tomorrow. Honestly, it wasn't the best riveting job I've done, but it is safe and all rivets meet the specs for shop head size. There are a few small dings in the skin. Nothing bad, and nothing that a little Superfil won't fix.


 
Aug 26, 2020     More riveting of the HS. - (2.0 hours)       Category: Empennage
Continued riveting on the riveting the spars and ribs to the HS skin


 
Aug 25, 2020     Right Rudder Build - (.5 hour) Category: Empennage
Since this was a previously owned kit I decided the included right rudder wasn't quite up to my standards so I began the build of the new right rudder. Today, I cut and deburred the rib clips.
 
Aug 25, 2020     More HS riveting - (2.5 hours) Category: Empennage
Continued to rivet the HS skin to the front spar and ribs. It's taking quite a bit of time to rivet this area due to it's inaccessibility, but it's getting done and is looking might fine.
 
Aug 24, 2020     Empennage Construction Techniques - (2.0 hours) Category: Empennage
Decided to see how others have built their empennage. Lots of different methods out there.
 
Aug 24, 2020     Riveting the HS-905 end ribs - (.5 hour) Category: Empennage
Had only a few minutes today but I managed to get the two end ribs riveted. Small steps, but at least it's moving forward.
 
Aug 23, 2020     Riveting the modified nose ribs and inspar ribs together - (.5 hour)       Category: Empennage
There are 10 fairly large rivets fastening the HS-904 and the HS-905 modified ribs together and to the front spar. Due to the angles that are inherent in the design, they are difficult to get to. The rivet squeezers, manual and pneumatic, would require a lot of modification in order to get in there, thus I was left with one choice and that was the good old rivet gun and bucking bar. Using an offset rivet set and the reliable tungsten bucking bar, we (my good friend Jeff R and I) managed to get the job done in quick order. Proving once again that good luck can offset bad skills One rivet is not too pretty, but its structurally sound. The other 9 are really good. Dodged a bullet here as drilling these bad boys out would have been difficult. So the shortest task gets the largest write up - go figure.


 
Aug 22, 2020     More HS riveting - (1.5 hours) Category: Empennage
Continued to rivet. Slow going due to tight quarters. But progress made nonetheless. The bottom forward spar to skin rivets are complete.
 
Aug 21, 2020     HS riveting - (1.5 hours)       Category: Empennage
Continuing to rivet the HS skin to the HS front spar


 
Aug 20, 2020     HS skin riveting - (4 hours) Category: Empennage
Paul and I continued clecoing and began riveting together, the HS skin and front spar assembly. This also included clecoing the center in-spar nose rib to the forward spar, HS skins and the in-spar ribs. There is very little space to get the job done as our arms are to almost to big to fit between the skins, but we got it started and it's going smoothly, but slowly.
 
Aug 19, 2020     Riveting the nose ribs to the HS skins - (2 hours)       Category: Empennage
With the help of my good friend Bob K we managed to get the nose ribs installed within the HS skins. Despite the tight access it was done smoothly and efficiently - okay, it was done with a lot of screaming and yelling and bloodletting. But it's done!


 
Aug 15, 2020     Riveting the Inspar Ribs - (4.0 hours)       Category: Empennage
Riveted the in-spar ribs to the spar, except the two middle ones which get attached later. I also riveted the two end nose ribs to the forward spar. Fitted the HS skins into the cradles and clecod the nose ribs in place.


 
Aug 14, 2020     Riveting the stringers and ribs - (3.0 hours)       Category: Empennage
The 2 spar stringers and 2 inspar ribs were riveted to the stringer web. The assembly was then clecod to the forward spar with all the other inspar ribs and the two outboard ribs- which were also riveted to the spar.


 
Aug 13, 2020     Primed the stringers. - (.5 hour) Category: Empennage
Decision made; I'll prime only non al-clad parts as priming the already protected surfaces just adds weight and cost. Of course there will be exceptions and that's fine. So, my SEM primer arrived today and I gave the stringers a couple of coats. I'll let them dry overnight although the label says less than an hour.
 
Aug 12, 2020     Countersinking and re-dimpling the ribs - (1. hour) Category: Empennage
Short day- yet again. Completed countersinking the spars. Re-dimpled all the HS ribs with a subsurface dimple set. The subsurface dimplers create a slightly deeper dimple for the skins to rest in. A friend gave me the dimple set to test out and we'll see how it goes. I may have to order another tool:-)
 
Aug 11, 2020     Countersinking the HS Rear Spar - (1 hour)       Category: Empennage
Countersinking continues on the rear spar. Short day due to other committments.


 
Aug 10, 2020     HS Dimpling and Countersinking - (5.0 hours)       Category: Empennage
Completed dimpling of the HS skins and completed countersinking of the forward spar leaving the rear spar to go. Note of caution: When using the C-Frame it is possible the die on the mandrel can come loose and adversely affect the subject skin leaving an unwanted dent. I suggest anyone using this setup consider taping the die to the mandrel to prevent this. The preferred tape of course would be duct tape. No need to ask how I know this:)


 
Aug 09, 2020     Dimpling & Countersinking - repeat thousands of times - (4.0 hours)       Category: Empennage
Began the dimpling of the HS skins and countersinking the HS front and rear spars. As usual, I ran into a few problems. After about a hundred countersinks my CS bit, bit the dust. So did my #40 dimple dies, apparent retainer ring failures as the dies fly off the C-Frame. I guess they're only good for about one aircraft. Anyway, new ones ordered from Aircraft Spruce. Meanwhile I'll have to borrow these from friends to keep the build going. I'm also teaching my friend Paul how these things are done. All in all, a good day getting things done and teaching new skills to my old buddy!


 
Aug 07, 2020     Deburring and Dimpling - (3.5 hours) Category: Empennage
I reexamined the ribs and decided it was best to flute the ribs. They were basically okay, but with little fluting they are now in perfect alignment. Now with fluting and deburring out of the way it's on to dimpling. All the HS inspar, front and HS ribs were marked to ID which rib holes to not dimple. The front ribs required a dimpling vise grip type tool to get into the front holes due to the limited clearance. The rest were easy, but time consuming to accomplish. With this complete, it was on to deburring the HS skins. Unlike my RV-7A build I decided to remove the blue film on the skins early in the process. Since this was initially a preowned kit, the blue film had been on for 7 years. Time to remove it! I then identified the holes to not dimple and clearly marked them. Also, I triple checked them to be certain they were correct. This is not the time to make an expensive mistake.
 
Aug 06, 2020     Completed Front Spar components deburring. - (6.0 hours) Category: Empennage
Finally, maybe, I think. I've completed the deburring of all the components for the front spar.
 
Aug 04, 2020     Completed front spar doubler and spar cap riveting. - (6 hours)       Category: Empennage
Completed riveting the spar caps to the spar as well as the doubler to the spar. After completing this riveting, I took to deburring all the HS inspar and front ribs. Modified two of the front and inspar ribs per the instructions.


 
Aug 03, 2020     HS Front Spar - (2.0 hours) Category: Empennage
Completed riveting of the front spar doubler to the front spar.
 
Aug 01, 2020     HS Front Spar - (2.0 hours) Category: Empennage
Began riveting the front spar doubler to the front spar. Taking a short hurricane break starting tomorrow so the remainder of the riveting will have to wait.
 
Jul 31, 2020     "Near" final drilling of front spar components - (2.0 hours) Category: Empennage
Completed final drilling, and countersinking of some front spar components. Primed the front spar doubler. Continued deburring front spar components.
 
Jul 30, 2020     Front spar caps - (4.5 hours)       Category: Empennage
Drilled and deburred both front spar caps. A couple of hundred precisely drilled and perfectly aligned holes. Only 10,000 more to go.


 
Jul 29, 2020     Horizontal Stabilizer Front Spar - (3 hours) Category: Empennage
Cut and deburred front spar caps and deburred the front spar and doubler.
 
Jul 27, 2020     Horizontal Stabilizer - (5 hours)       Category: Empennage
Completed the rear horizontal stabilizer spar, except for torquing the center bearing bolts.


 
Jul 26, 2020     Rudder inspection and Horizontal Stabilizer start - (5.5 hours)       Category: Empennage
July 24, finally getting underway! Since this was a 'pre-owned kit', a close and detailed inspection of the completed parts was accomplished. The vertical stab looked okay as did the left rudder. The right rudder however, was not up to my standards. I ordered the new parts from Van's and switched gears to start on the horizontal stabilizer. July 25/26 The doubler was deburred and then primed. The horizontal spar deburring took a little longer to do but it was completed just as the paint dried on the doubler. Clecoed them together and drilled the remaining holes. Then temporarily installed the hinge brackets for final drilling.


 


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