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Project: DR_DAVE'S_RV-10 -
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Builder Name:	DAVE LEHMAN -

Project:	Vans - RV-10 - VIEW REPORTS
Total Hours:	452.1
Total Flight Time:
Start/Last Date:	Oct 01, 2020 - Feb 03, 2026

Friendly URL:	https://eaabuilderslog.org?s=DR_DAVE'S_RV-10

Home or Last Project Picture

Feb 17, 2024 Replaced Finished Assemblies on Wall - (2 hours) Category: Tail Feathers

Remounted finished assemblies to wall mounted shelves for earthquake prevention.

Feb 16, 2024 Tail Tie Down - (4 hours)

Category: Tail Feathers

PAge 10-2 Rev 1 Step 1 Fabricated Tail Tie Down

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Feb 14, 2024 IA progress inspection - (2 hours)

Category: Tail Feathers

Page 9-20 Rev 1 Step 2 Safety Wiring piano hinge. Demo'd and taught by Al Hathy; EAA Tech counselor EAA #398190. Al demonstrated installation technique for safety wire. Al then supervised and approved my safety wiring of the second piano hinge piin. Al also inspected progress on finished vertical stabilizer, rudder, horizontal stabilizer, elevators and trim tabs.

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Feb 11, 2024 Counterweight - (2 hours) Category: Tail Feathers

Page 9-20 Rev 1 Step 1

Feb 10, 2024 Elevator Counterweight - (2 hours) Category: Tail Feathers

Page 9-16 Rev 1 Step 1 thru 6, step 9 counterweight and extra weight installation per SB-00043 Torque 28 in/lbs (10 in/lbs and 8 in/lbs breakaway)

Feb 10, 2024 Riveting elevator trailing edges - (3 hours) Category: Tail Feathers

Page 9-15 Rev 1 Continued Step12 - Riveting elevator trailing edges

Feb 09, 2024 Riveting Elevator Trailing Edges - (3 hours) Category: Tail Feathers

Page 9-15 Rev 1 Step 11 & 12 Riveting elevator trailing edges

Jan 23, 2024 Riveting Hinge Halves to Elevator - (3 hours) Category: Tail Feathers

Page 9-19 Rev 1 Step 7 - Riveting the hinge halves to the elevator 2X sides

Jan 21, 2024 Riveting Hinge Halves - (6 hours)

Category: Tail Feathers

Designed a wheeled, height adjustable mount for the pneumatic squeezer. Harbor Fright Adjustable Wheel Seat (removed padded seat) HF Arbor Press modified to hold Pneumatic Squeezer. Riveting hinge halves to trim tab.

Pneumatic Press Holder

Pneumatic Press Holder

Riveting Trim Tab Hinge Halve to Spar

Riveting Trim Tab Hinge Halve to Spar

Riveting Trim Tab Hinge Halve to Spar

Looks good!

Completed riveting hinge halve to spar/skin

Completed riveting hinge halve to spar/skin

Completed riveting hinge halve to spar/skin

Completed riveting hinge halve to spar/skin

Completed riveting hinge halve to spar/skin

Jan 20, 2024 Elevator Trailing Edge - (5 hours)

Category: Tail Feathers

Elevator Trailing edge AEX wedge and foam; cleco'd trim tab hinge halves to spars using same pro-seal.

AEX trailing edge wedge

Trim Tab Hinge Halves

Tank Sealant

Tank Sealant on Hinge Halve

Hinge Halves with Sealant

Trim Tab Hinge Halves Sealed

Elevator Foam Rib with sealant

Elevator Foam Rib with sealant

Sealed and Cleco'd

Sealed and Cleco'd

Sealed and Cleco'd

Sealed and Cleco'd

Jan 14, 2024 SB-00043 - (6.5 hours)

Category: Tail Feathers

SB-00043 for rear spars/skin area, what a potential mess, also 9-18 step 9 - trim tab foam insets, 9-16 step 7 - rier WD-415 to trim cable bracket, step 19 step 1-2, clean up.

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Jan 13, 2024 SB-00043 more - (7.3 hours) Category: Tail Feathers

SB-00043 make v-supports, insert elevators, clean with vacuum, add clamps to skin-spar area where not riveted, prepped TE wedge, collected board, weights, etc

Jan 13, 2024 SB-00043 - (2 hours) Category: Tail Feathers

trim tabs - rivet spar to skins,

Jan 11, 2024 Trim Tabs - (3 hours) Category: Tail Feathers

trim tabs, prime area under the horns, prep elevators for SB-00043, trim tab horns riveted to skins and spars (lower only)

Jan 10, 2024 Riveting skins Category: Tail Feathers

rivet skins to spars except skins aft of rear spar E-1007 (for trailing edge wedge insertion later)

Jan 06, 2024 re-prime - (2 hours) Category: Tail Feathers

re-prime tip ribs, spar and counterweights

Jan 05, 2024 Trim tab trailing edges - (2.0 hours) Category: Tail Feathers

Trim tab trailing edge bends, need to touch up epoxy tip ribs, re-alodine scratches area on E-903

Jan 02, 2024 Begin prep for SB-00043 - (2.5 hours)

Category: Tail Feathers

Prep elevators for the SB-00043 sealant addition.

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Jan 01, 2024 Tip Ribs - (5.0 hours)

Category: Tail Feathers

Tip ribs riveted together added counterbalance skins. Riveted tip ribs to elevators. Riveted skins to spars and tip ribs. Cut PVC foam to final trim tab and elevator sizes.

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Dec 26, 2023 Tip Ribs LCP Replacments - Epoxy Prime - (3 hours)

Category: Tail Feathers

Took replacement E-903 and E-904; E-913 plus the replacement Trim Tab Spars E-920 and E-1020 after alodining and epoxy primed them in the paintbooth.

E-913 ready for priming

All set ready for priming

All set ready for priming

All set ready for priming

All set ready for priming

All set ready for priming

E-913 all primed

All primed

Ready for assembly 2.0

Trim tabs prepped using old LCP Spars

Trim tabs prepped using old LCP Spars

Nov 28, 2023 Elevator Trim Tabs - (6 hours)

Category: Tail Feathers

Bending of trim tabs at elevator. Note: I etch primed the overlap parts prior to this bend. Also final bend on elevator chord with old LCP Spars in place. (New Non-LCP spars are dimpled, machine countersunk and alodined, awaiting epoxy primer)

Tab in wedge brace

initial bending of inside tab

looking OK

That is fine

Top skin tab coming down

Looks good,  a little more bend

wedge out

need to clean adhesive off

Aug 13, 2023 Elevator Assembly - Continued

Category: Tail Feathers

Ok. Back to the project. Used long bucking bar to install rivets on the rear spar of elevator. Not an issue at all, #3 rivet gun @ 37PSI. Used PVC pipe on pop- rivet squeezer for leverage on inner LP4-3 blind rivets. Rear spar LP4-3 bilnd rivets were easy with the Harbor Fright Pneumatic Squeezer. Front Spar a little difficulty with rolling rivets (mostly cosmetic, sorry Tony B) I think we need to use other longer dies for the pneumatic squeezer as I suspect the long travel may be the issue.

Spar along trim tab easy to set.

Hard to reach rivets

Custom long Bucking Bar

Bucking BAr with protective tape

Finished Results

Looking inside

Looking inside

Finished rear spar riveting

Blind riveting stringers

Blind riveting stringers

Blind riveting stringers

End with access panel

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Blind riveting stringers

Blind riveting stringers

Jan 03, 2023 Back Riveting Ribs to Skin - (3 hours)

Category: Tail Feathers

Getting pretty fast back riveting the -3.5 rivets used 35PSI #2 gun, for the -3's dropped it to 30PSI. All went well except found, after finishing the top right skin, there was a rib without sub-dimples, Ope! (Mary!!!!!) Drilled out 8 rivets without an issue, dimpled rib, then promptly set the 1st rivet at 90PSI! (wrong hose) Oh, well, something wrong on all sub assemblies will humble a builder.... just a slight deformation on the upper skin. in retrospect, I probably should have just left it alone the 90PSI rivet was pretty flat, but still had 7 nice rivets to take up the slack and it was in the center of the rib. Shhhhh!

E-1015 Reinforcement plate back riveting

Skin ready for ribs installation

Lots of -3 rivets

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Back Riveting Ribs to Skins

Back Riveting Ribs to Skins

Back Riveting Ribs to Skins

Back Riveting Ribs to Skins

Window shade strips for back rivet plate reference

Window shade strips for back rivet plate reference

Top Skin ready to back rivet

Top Skins ready to back rivet

Top Skins ready to back rivet

Jan 02, 2023 Elevator Assembly - (9 hours)

Category: Tail Feathers

Started assembling Elevator, riveted Tip Ribs, had missed the 6X end dimples (can't use DRDT, needed pneumatic squeezer) Also, sub-skin dimpled 6X holes at skin/counterweight overlap. Seems rivets don't sit as flush after expoy primer, unsure if from under dimpled or excessive primer. So I re-dimpled one set of counterweight skins, appears to have helped. (Cannot feel any rivets with rub test before re-do, but was optically annoying) Ran short of about 5X -5 rivets for doublers. unsure why, maybe too many previous misteaks. Ground down a few -6 rivets to length to make up difference. Will order more just for stock. Elevator horns, little tough to install rivets into holes, again, suspect too much primer in holes, scraped out primer for install, and actually just reamed a few holes. Prepped back rivet plate and re-waxed.

Tip Ribs Riveting together

Tip Ribs Riveting together

Counterweight skin riveting

Counterweight skin riveting

Counterweight skin riveting

Counterweight skin riveting

Counterweight skin riveting

Tip Ribs Riveting together

Counterweight skin riveting

Level to ensure good squeeze

Hinge Reinforcement Plates

Hinge Reinforcement Plates

Hinge Reinforcement Plates

Flush rivets for mounting E-905 root ribs

Inside view of Horn Rivets

Flush rivets for mounting E-905 root ribs

Flush rivets for mounting E-905 root ribs

Elevator Horn Rivet

Inside view of Horn Rivets

Elevator Horn Rivet

Alodine area was masked for for foam ribs

Masking for Foam Ribs removed

Dec 30, 2022 Elevator and Trim Skin Dimple, Priming Innards - (12 hours)

Category: Tail Feathers

Mary dimpled the 4 elevator skins and the 2 trim skins. I prepped the paint booth for priming and added additional masking of rear spars for foam ribs. Epoxy primed all elevator and trim tab parts that were previously alodined. Counterweights trimmed, Fubar'd one weight, so I re CSK hole on other side and filled front side, each set weighs in at 1125 gms. Prepping the lead weights, rough cut weights on bandsaw with a 6-TPI blade. The blade normally used for cutting the aluminum ribs is a 24-TPI blade, too fine for lead. A farrier hoof rasp made short work of the remaining trimming, as well as the high ridge on the back side of two of the counterweights.

Paint Booth Lineup A

Paint Booth Lineup B

Paint Booth Lineup C

Paint Booth Lineup D

Paint Booth Lineup E

Epoxy Primed A

Epoxy Primed B

Epoxy Primed C

Farrier Hoof Rasp and Bastard File

Counterweight Pair

Ready for Install

Dec 29, 2022 Prep and Alodine Elevator and Trim parts. - (7.5 hours)

Category: Tail Feathers

Alodine preparations, cleaned all metal with acetone. Alodined all elevator parts and trim spars/hardware, hanging to dry.

Acetone Cleaned and layout in order

Tip Rib Parts ready to Alodine

Drying in the Beer Cave

Drying in order of placement

Drying small item

Drying Parts

Drying parts B

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Dec 26, 2022 Etch Prime Elevator Skins - (7 hours)

Category: Tail Feathers

Elevator and trim tab skins prepped for Etch Priming with skins masked for foam ribs. Used orbital sander with maroon scotebright to clean off micro scratches. all parts primed with SW P60G2

Roughed up area for foam rib

Roughed up area for foam rib B

Roughed up area for foam rib C

Masking area for priming A

Masking area for priming B

Masking Trim skin for priming A

Masking Trim skin for priming B

Masked Skins for Priming

Dec 24, 2022 Trim Tab Horns - (2 hours)

Category: Tail Feathers

Used opposite tab with cleco to mark cut lines on trim tab horn. Assures adequate hole spacing to edge.

Marking Trim Horn A

Marking Trim Horn B

Marking Trim Horn C

Marking Trim Horn D

Ready for deburr

Ready for Debur

Deburred while mated

Finished Pair

Finished Sets L - R

Dec 15, 2022 Elevator Spars - Machine Countersink, Dimpling Tip Ribs - (1 hour)

Category: Tail Feathers

Machine countersink areas of spars and dimple remaining holes. Dimple tip ribs, including small gap area technique using pliers. Finished with deburring spars on Scotchbrite wheel.

Tip Rib Dimple Tools B

Tip Rib Dimple Tools A

Tip Rib Dimple E

Tip Rib Dimple D

Tip Rib Dimple C

Tip Rib Dimple A

Tip Rib Dimple B

Front Elevator Spar A

Front Elevator Spar B

Front Elevator Spar C

Rear Spars A

Rear Spars B

Rear Spars C

Rear Spars D

Rear Spars E

Nov 30, 2022 HS Finished!! - (3.5 hours)

Category: Tail Feathers

Final Rivets of rear spar. Also, a slip with the bucking bar and the results - ope! At least it is on the bottom side.

HS Rear Spar A

HS Rear Spar B

HS Rear Spar C

Double inside view

HS Finished A

HS Finished B

Bucking Eh!

Bucking A

Bucking Aye

Nov 29, 2022 Bottom Side HS - (3.1 hours) Category: Tail Feathers

Researching torque values, riveting skins

Nov 28, 2022 HS final steps - (3.5 hours)

Category: Tail Feathers

Ribeting Rear Spar to Skin; Drill out some bad rivets, primer touch up and installing hardware.

Rear Spar Rivets

Final Rib Rivets

Rear Spar A

Rear Spar B

Nov 27, 2022 Bottom Skins - (1.5 hours) Category: Tail Feathers

Bottom Skin Rivets

Nov 25, 2022 Bottom Skins - (3.5 hours) Category: Tail Feathers

Bottom Skin Rivets

Nov 24, 2022 H Spar Rivering HS-1015 Stringer - (8 hours)

Category: Tail Feathers

Ah. The dreaded HS-1015 Stringer Invisible Rivets. I have been riveting in a horizontal position placing the frame on two banker boxes with a soft blanket to position. For the invisible rivets I balanced the tungsten rivet bar on my first two fingers and pushed up on the rivet. After placing the rivet gun on the skin, I reposition the rivet bar to "feel" a horizontal position. A known burst of the gun set the rivet to pretty darn close to what I wanted. I used a telescoping mirror to inspect results, all worked well! (Black Gorilla tape is used on bucking bar to protect stringer from damage.) PM me for a video of this technique if desired - dl

Here we go!

Ready for the dreaded HS-1015 riveting

HS-1015 Stringer Riveting A

HS-1015 Stringer Riveting B

Looking at HS-1015 Stringer Rivets A

Looking at HS-1015 Stringer Rivets B

HS-1015 Stringer Riveting C

Looking Inside A

Looking Inside B

Looking Inside C

Looking Inside D

Looking Inside E

Looking Inside F

Bad Rivet A

Bad Rivet B

Bad Rivet C

Replaces, chipped primer (was touched up later)

Nov 23, 2022 Bottom and Top Skins - (7.5 hours)

Category: Tail Feathers

Riveting Nose Ribs. After IA look of progress, installed forward spar with pop rivets and began riveting skin to forward spar.

Front Spar Riveting A

Front Spar Riveting B

Nose Rib to Skin A

Nose Rib to Skin B

Front Spar to Nose Ribs (Compression rivet) A

Front Spar to Nose Ribs A

Front Spar to Nose Ribs B

Here we Go! Lots of bucking around

Nov 13, 2022 Nose Ribs to Skin - (2 hours)

Category: Tail Feathers

Riveting Nose Ribs to HS skins.

VS Inspected and ready to seal up innards

VS and HS Ribs/Spar

HS sitting, well, horizontal

VS Rib Closing

VS Final rivets A

VS Final rivets B

Tricky Flange Gap A

Tricky Flange Gap B

Tricky Flange Gap Clamping Trick

Nice Results

Flange Gap A

Rivet showing gap

Tool worked!

Rudder Stop

Rudder Stop Hole Alignment

Rudder Stop Bolts Installed

HS skin ready to populate

HS skin ready to populate B

HS skin ready to populate C

Ready to Rivet

Oct 29, 2022 Elevator Parts placement and Tip Ribs - (4.5 hours)

Category: Tail Feathers

Adjusted tip ribs for match counterbalance of skin. Bend closeout tabs and ream holes as necessary.

Match Drilling Shear Clip

Trailing Edge Wedge

Trailing Edge Wedge

Tip Ribs (Lost of adjustment needed)

Tip Ribs

Raw Assembly

Oct 28, 2022 Elevator Gusset - (7 hours)

Category: Tail Feathers

Tip Ribs adjustment, really scratched up. Installed gussets and reamed holes to final size.

Gusset Position A

Gusset Position A

Gusset Position B

Gusset Position C

Gusset Position D

Gusset Position

Gusset Position

Gusset Position

Oct 23, 2022 VS Nose Ribs and Spar Riveting - (5.8 hours)

Category: Tail Feathers

Nose ribs installed, skin to spar, includes a bad compression rivet at bracket and drill out images. (Changed compression speed to prevent this - PM me for technique)

Tip Rib Check

Tip Rib Done

Tip Rib Clamping

Tip Rib Clamp

Spar Pneumatic Riveting

Spar Pneumatic Riveting

Spar Pneumatic Riveting

Spar Pneumatic Riveting

Spar Pneumatic Riveting

Spar Pneumatic Riveting

Spar Pneumatic Riveting

Spar Pneumatic Riveting

Bad Rivet

Bad Rivet

Bad Rivet

Bad Rivet

Bad Rivet

Oct 05, 2022 Tip Ribs - Long Day - (6.5 hours)

Category: Tail Feathers

OK. Spent considerable time tweaking the Inboard and Outboard nose ribs to straighten them so as to align to the Counterbalance Skin. Finally got what I deemed acceptable, Reamed the 3/32, 1/8 and 3/16 holes, no problem. (Page 9-2 Step 4-6) Then on to Step 7-8 for the Shear Clips. Finished the night with Page 9-3 Steps 1-3, for the Close-Out tabs. Used a part from a metal bending brake covered with blue painters tape to protect. DId NOT use rivet gun set on low, simply tapped with a piece of white oak scrap full length of tab.

Using metal  brake for bend

Close Out Tabs

Close Out Tabs

Close Out Tabs

Close Out Tab angle check

Using Pliers to reduce over-seaming

Tip Ribs

Tip Ribs

Tip Ribs

Tip Ribs

Tip Ribs

Tip Ribs

Oct 04, 2022 Elevator Tip Ribs, Spar Adjustments - (1.0 hour)

Category: Tail Feathers

Verified spars were still at 90 degrees. Didn't like the looks of the original tip ribs from Vans (E-903, E-903), so I ordered replacements. These tip ribs are not much better, in pretty bad shape, scratches, some corrosion, serious Scotchbrite work was needed on them. I will Alodine and Epoxy prime but still, needed to repair before attempting to shape.

90 degree check.jpg

Oct 03, 2022 Elevator Ribs - (3.3 hours) Category: Tail Feathers

Still deburring and cleaning up Elevator Ribs

Oct 01, 2022 Elevator Ribs - Deburring - (2.3 hours) Category: Tail Feathers

Deburring Elevator Ribs Step 2

Sep 07, 2022 Assembling Front Spar - (1 hour)

Category: Tail Feathers

Finishing up Page 8-11 with Steps 2-3

Match Drilling Doublers for Elevators

HS Skin in bracket

VS after inspection ready for final rib riveting

Assembling HS Spars to Ribs

HS Skin naked

HS Skin with blue vinyl to be removed from interior

Sep 05, 2022 Elevator - (1.5 hours) Category: Tail Feathers

Page 9-2 Step 1. Used new 24TPI bandsaw blade to cut E-1008 Elevator Ribs into Parts A-B.

Sep 02, 2022 Front Spar and Nose Rivets - (1 hour) Category: Tail Feathers

Placement of Nose Ribs into skin in preparation for riveting.

Aug 27, 2022 Riveting Inspar Ribs and Stringer Web - (3.5 hours) Category: Tail Feathers

Page 8-10 Steps 1-2 To rivet Stringer and Stringer Web together; Page 8-11 Riveting the Inspar Ribs

Aug 26, 2022 Epoxy Priming HS Parts - (3 hours) Category: Tail Feathers

Epoxy Primed parts for HS

Aug 23, 2022 Countersinking Replacement Stringers - (3 hours) Category: Tail Feathers

Machine Countersink HS-1014 HS-1015 Replacement Stringers to 0.007" for skins.

Aug 22, 2022 New HS-1014 and HS-1015 Stringers - (2.3 hours) Category: Tail Feathers

Took replacement stringers and cut/deburred (Page 8-4 Steps 1-2)

Aug 19, 2022 HS Alodine Parts - (1 hour) Category: Tail Feathers

MAry's assistance, Alodined HS spars/ribs and misc parts

Aug 18, 2022 HS Stringer Web and Rear Spar - (1.5 hours) Category: Tail Feathers

Mary dimpled parts using the DRDT

Aug 17, 2022 Dimpling HS Parts - (4 hours) Category: Tail Feathers

Continuation of Page 8-9 Mary, my Wife, assisted in Page 8-9 Steps 1-8. For cleco assembly, drilling and dimpling (Mary dimpled all parts using the DRDT)

Aug 15, 2022 HS Stringers, Stringer Web and Rear Spar Assembly. - (3.0 hours)

Category: Tail Feathers

Mary, my Wife, assisted in Page 8-9 Steps 1-8. For cleco assembly, drilling and dimpling (Mary dimpled all parts using the DRDT)

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Aug 14, 2022 More Riveting Progress - (10 hours)

Category: Tail Feathers

Page 8-6 step 1-2 for . Front Spar Doubler, Spar Caps, and HS-1008 (L-R) Front Spar Attachment Brackets. Page 8-8 Steps 1-8 for match drilling and reaming of holes. Screwed up the HS-1014 and HS-1015 Stringers by countersinking wrong holes. Ordered new parts from Vans (Got them in 3-days!!!)

Ribs:Spars in Skin A.jpeg

Ribs:Spars in Skin B.jpeg

Ribs:Spars in Skin C.jpeg

Ribs:Spars in Skin E.jpeg

Ribs:Spars in Skin F.jpeg

Ribs:Spars in Skin G.jpeg

Riveting Doubler to HS Spar.jpeg

Riveting Spar A.jpeg

Riveting Spar Attachement Bracket.jpeg

Spar Attachment Bracket A.jpeg

Spar Attachment Bracket's Riveted.jpeg

Aug 13, 2022 Riveting HS Spars - (6.0 hours)

Category: Tail Feathers

OK. Back in shop. All parts Alodined and Epoxy Primed. Back to page 8-2 Step 5-6 to rivet the Rear Spar Doubler, Hinge Brackets,. Page 8-3 Step 2 to bolt on inboard hinge bracket.

Bracket with Hardware.jpeg

HS Doubler Final.jpeg

HS Doubler top-Side image.jpeg

HS Spar - Long view.jpeg

HS Spar Backside of Doubler.jpeg

HS Spar with Brackets Clecoed.jpeg

HS Spar with Doubler Riveted.jpeg

HS Spar with Doubler and Brackets.jpeg

HS Spar with Hinge Brackets II.jpeg

HS Spar with Hinge Brackets.jpeg

Hinger Brackets Close-Up.jpeg

Imboard Hinge Bracket Fastened.jpeg

Aug 03, 2022 Alodine and Prime HS Ribs - (8.5 hours)

Category: Tail Feathers

Prepped Ribs/Misc parts for Alodine Process, (Scotch Brite defects and Acetone wipe) Let parts cure for a few days before epoxy priming them, also (scotch brite was completed before dimpling) and primed inside of skins

HS Ribs Modified and Deburred.jpeg

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Apr 24, 2022 Counterinking HS Spars - (8 hours)

Category: Tail Feathers

Decided to jump ahead and perform Step 8, Pg 8-8 to countersink both HS spars, doublers and ribs. My process will have these items Alodined and epoxy primed, thus wanted to do machine work prior.

Forward Spar Countersink A.jpeg

Forward Spar Countersink B.jpeg

Forward Spar Countersink C.jpeg

Forward Spar Countersink F.jpeg

Forward Spar Countersink E.jpeg

Forward Spar Countersink D.jpeg

Forward Spar Countersink G.jpeg

Apr 23, 2022 HS Rib Mods and Final DeBurr - (10 hours)

Category: Tail Feathers

HS Rib Mods for Stringers A.jpeg

Rib Mod %22A & B%22.jpeg

Rib Mod %22B%22.jpeg

Rib Bend 9 degrees A.jpeg

HS Rib Bend B.jpeg

Rib Bend 9 degrees B.jpeg

Rib Bend 9 degrees C.jpeg

Rib Bend 9 degrees D.jpeg

Rib Bend 9 degrees E.jpeg

Rib Bend Reference 90 degrees minus 9 = 81!.jpeg

Rib Bend Reference 90 degrees plus 9 = 99!.jpeg

Rib Bend 9 degrees A.jpeg

Rib Bend 9 degrees B.jpeg

Rib Bend 9 degrees C.jpeg

Rib Bend 9 degrees D.jpeg

Rib Bend 9 degrees E.jpeg

Rib Bend Reference 90 degrees minus 9 = 81!.jpeg

Rib Mod %22A & B%22.jpeg

Rib Mod %22A%22.jpeg

Rib Mod %22B%22.jpeg

HS Bend Jig A.jpeg

HS Rib Bend A.jpeg

HS Rib Bend B.jpeg

HS Rib Bend C.jpeg

Mar 14, 2022 Milling of HS Spars and Doublers - (1.0 hour)

Category: Tail Feathers

1-Front-Rear Spar - RAW.jpeg

1-HS H1008-R Raw Cuts.jpeg

2-HS H1008-R Raw Cut II.jpeg

D-HS-1008R Face View.jpeg

H Spar countersink I.jpeg

H1008-L & R were swapped!!!.jpeg

H1008-L and R side by side.jpeg

H1008-R Final A.jpeg

H1008-R Final B.jpeg

H1008-R Final C.jpeg

H1008-R Final D.jpeg

H1008-R-L CNC Drilling saved me!.jpeg

HS Double Countersink Closeup.jpeg

HS Spar Caps match drilling.jpeg

HS Spar Doubler Countersink.jpeg

HS spar caps drilling II.jpeg

HS spar caps drilling III.jpeg

HS1008 Match Drilling II.jpeg

$gallery thumbnail$

HS1008 Match drilling.jpeg

HS1008 drilling chips II.jpeg

HS1008 drilling chips.jpeg

HS1008- closeup.jpeg

HS1008-L Match Drilling.jpeg

HS1008-LR Match Drilled.jpeg

HS1008R match drilled.jpeg

Mating H1008-R-L.jpeg

Mar 05, 2022 Rudder Counterweight Install - (4 hours)

Category: Tail Feathers

Had fun forming the LE for the Rudder Counterweight. After folding skins I found I was slightly off on my initial fold line. to prevent a crease I took the lead weight and carefully used a propane touch to melt the outside edges and have the molten material flow towards where the screws would soon come though skin. Allowed to slowly air cool and then tamped remaining slight high areas with ball peen hammer to final dimension counterweight. I also etch primed the overlap skins for protection. The apparent "Line" in the finished primer image is actually from a double prime, I moved the blue masking tape and thus have extra layer primer toward seam. Came out sweet! (Was able to defer page 7-10 Step #4 as there is zero "pillowing" )

Match Drilling Rudder Counterweight skins.jpeg

Match Drill Skins -B.jpeg

Match Drill Skins - C.jpeg

PAGE 7-10 Step 1, Para 3.jpeg

Not too bad....jpeg

Rudder Counter Weight Nutplate install B.jpeg

Rudder Counter Weight -Nutplates installed.jpeg

Rudder Counterweight - side view.jpeg

Rudder Counterweight - other side view.jpeg

Rudder Counterweight showig smooth seam II.jpeg

Rudder Counterweight - Final showing sm0oth seam.jpeg

Rudder Counterweight - Finished.jpeg

Rudder Counter Weight A.jpeg

Finished Rudder - Side View.jpeg

Mar 04, 2022 Rudder Leading Edge - (12 hours)

Category: Tail Feathers

Went to Lowes for the 1 1/4" dowel for rolling the LE. Cut a small 6" piece off the roll for the smaller LE at the top of the Rudder. NOTE: If dowel diameter is too small, i.e. 1"; the leading edge radius will be too small with the edges meeting in a V, if the diameter is too large, i.e. 1 1/2" the LE radius will be too large with the edges meeting with a large gap, i.e not flush. I used a pipe wrench and vise grips which allowed me to relax and hold rolled LE skin in position as all the metal slowly stretched (solo operation). Duct tape was all I used on the skin and dowel. I also used my fingers to final shape the last 1/2" of the skins to make a nice overlap (See progression images) Be patient, learn YOUR technique. I also etch primed the skins due to the overlap both on the LE and the Rudder counterweight. Bought the "Harbor Fright" pneumatic riveter which after adding oil and practicing on scrap, worked just fine (used a rag over outlet as it sneezes oil when tilted on its side)

1- LE Unrolled Look.jpeg

2-LE Beginning of Roll (A).jpeg

2a-Rudder Leading Edge Curling C.jpeg

3-LE Beginning of Roll (AA).jpeg

3a-Rudder Leading Edge Curling A.jpeg

4-LE Beginning of Roll (B).jpeg

5-LE Beginning of Roll (C).jpeg

6-LE Beginning of Roll (C0.jpeg

7-LE Overlap, not acceptable.jpeg

8-Not even Close LE overlap.jpeg

9-LE Working in progress (A).jpeg

10-LE Better.... (E).jpeg

11-LE Close but not there yet (D).jpeg

12-Pretty Good overlap seal - Leading Edge.jpeg

13-LE Overlap - Ther ya go!.jpeg

14-LE overlap, I'll take that....jpeg

15-LE Almost a flush bend (A).jpeg

16-LE Before cleanup and prime (A).jpeg

17-LE Before Cleanup and Prime (B).jpeg

18-LE Before Cleanup and Prime (C).jpeg

19-Harbor Fright Pneumatic Blind Rivet Gun.jpeg

19a-Rudder Leading Edge Curling B.jpeg

19b-Rudder Leading Edge Curling D.jpeg

19c-Rudder Leading Edge Curling E.jpeg

20-Riveting LEading Edge (A).jpeg

21-Rudder Leading Edge Curling - FINAL A.jpeg

22-Rudder Leading Edge Curling - FINAL B.jpeg

23-Rudder Leading Edge Curling - FINAL C.jpeg

24-Rudder Leading Edge Curling - FINAL E.jpeg

25-Rudder Leading Edge Curling - FINAL F.jpeg

26-Rudder Leading Edge Curling - FINAL G.jpeg

27-Rudder Leading Edge Inside A.jpeg

28-Rudder Leading Edge Inside B.jpeg

29-Rudder Leading Edge Inside C.jpeg

30-Rudder Leading Edge Inside D.jpeg

31-Rudder Leading Edge Inside H.jpg

Mar 03, 2022 Rudder Trailing Edge - (10 hours)

Category: Tail Feathers

Jig set up for the pneumatic riveter and special flush rivet tool (Cleaveland Tool) set the trailing edge rivets in 4 stages of setting (light touch just enough to hold into hole, 1/32 more, 1/32 more, then final seat), initial squeeze was on the centermost rivet, then #10 left, #20 left, #10 right #20 right, then #5 L-R, #15 L-R, then marked remaining A-B-C-D. Pneumatic riveter was on a caster cart, thus able to roll left and right without disturbing position of trailing edge.

Mary with the BF anvil.jpg

Rudder Trailing edge cleco'd.jpeg

Pneumatic Squeezer A.jpeg

Pneumatic Squeezer D.jpeg

Pneumatic Squeezer C.jpeg

Pneumatic Squeezer B.jpeg

Rudder Trailing Edge - A.jpeg

Rudder Trailing Edge - B.jpeg

Rudder Trailing Edge - C.jpeg

Rudder Trailing Edge- Final A.jpeg

Rudder Trailing Edge- Final D.jpeg

Rudder Trailing Edge- Final E.jpeg

Rudder with Spar Install C.jpeg

VS with Spar Install A.jpeg

Jan 08, 2022 Rudder Assembly - (12 hours)

Category: Tail Feathers

Page 7-7 Back riveted stiffeners to skins, top rib half and bottom rib half to skins Page 7-8 riveted shear clips to stiffeners and attached skins together. Designed thin mini bucking bar for rivet on R-1004. Page 7-10 completed.

Rudder Stringers.jpeg

Rudder stringers ready for back riveting.jpeg

Stringer Riveting.jpg

Rudder Skins.jpg

Rudder Skins assembly A.jpeg

Rudder Stiffeners B.jpeg

Inside of Rudder G.jpg

Rudder Stiffeners C.jpeg

Rudder Stiffeners D.jpeg

Rudder Stiffeners A.jpeg

Rudder Stiffeners E.jpeg

Rudder Stiffeners H.jpeg

Rudder Stiffeners F.jpeg

IMG_7352.jpg

Rudder Spar Install A.jpeg

Rudder Spar Install C.jpeg

Rudder Spar Install B.jpeg

Bucking Bar Design P.jpg

Bucking Bar Design J.jpg

Rudder Spar CCR264SS-3-2 Blind Rivet.jpeg

Dec 31, 2021 Rudder Innards Assembly - (2.0 hours)

Category: Tail Feathers

Assembled the innards for the Rudder. Pneumatic Squeezer really made things smooth and sweet! Also, took VS and Rudder skins into paint booth to Scotch-Brite inner surface and clean with M.E.K. Will touch up with SB and Acetone before acid-etch priming interior surfaces.

A-Bottom Rib Assembly.jpeg

B-inside view Bottom Rib Assembly.jpeg

C-Rudder Horn Attachment to Bottom Rib Assembly.jpeg

D-Rudder Horn Flush Rivet View.jpeg

E-Spar Reinforcement Plate R-607PP.jpeg

F-Spar Reinforcement Plate R-608PP.jpg

G-Inside view of R-608PP.jpeg

H-Vertical Stabilizer Skins Scotch-Brite and Cleaned.jpeg

I-Rudder Skins Scotch Brite and Cleaned.jpeg

Dec 29, 2021 Assembly of Vertical Stabilizer (sans skin) - (12.0 hours)

Category: Tail Feathers

Assembled parts for Vertical Stabilizer, times included making a leveling jig for the pneumatic squeezer, countersinking a few missed holes on rear spar doubler and etch priming results. Good practice drilling out deformed rivets. Will ask Wife for assistance on riveting skins. VS all ready for skins. But will assemble Rudder next as I need to etch primer the interior surfaces of the 3 skins. (Note: While proofreading entry and images I noted a missing AN426AD4-7 rivet! Dumbass!)

A-Jig for pneumatic Squeezer.jpeg

B-Level Jig for Setting Rivets.jpeg

BB-Leveled .jpeg

C-Pneumatic Results.jpeg

D-VS-1003 Rear Spar Close-Up.jpeg

E-Ready for skinning.jpeg

F-VS ready for the skins.jpeg

Jul 01, 2021 Still on the road Category: Tail Feathers

Still on the road working, usually off just before OSH, then we'll be back in the shop. Look for me at OSH, I'll be wearing a ball cap and sunglasses, oh, and a Hawaiian shirt

Apr 26, 2021 Back to Work Category: Tail Feathers

I'm back to work for a while. Won't be in the shop until further notice.

Feb 10, 2021 Elevator Spar - (5 hours)

Category: Tail Feathers

Deburred elevator spar and doubler. Dang thing is 11 feet long! Lots of work here. (also made some images for folks beginning this project)

Stamp artifacts on edge of doubler

Stamp edge

Deburr tool

V-shaped debur tool

Getting there

Inside Doubler more difficult to access

Die Grinder ScotchBrite Wheel (well worn)

Still shows scratches

Dremel Tip with Modified ScotchBrite pad.

ScotchBrite wheel on Die Grinder

Close

IMG_2688.jpg

Closer to what I want

There ya go!

IMG_2676.jpg

What happens when you slip with deburr tool

Slip with debur tool - more work

Had to wet sand scratch out of doubler.

Elevator Spar debur outcome

Spar closeup

Elevator Spar deburred and polished

Spar

Feb 02, 2021 Rudder - (10 hours)

Category: Tail Feathers

Lots of prep for Rudder skins. Then cleco assembly to check if match drill (reaming) is needed on holes. Some parts are now final drilled from Vans so I can check sizing, inspect and debur as needed, then dry assemble for fit. Trailing edge piece is final drilled also. (Lucky-Dog!)

Rudder Skins

Skins and Skins

Ready for Dimpling

Stiffeners and Ribs

Skins attached for Match Drilling

No Match drilling required

Rudder guts

Cleco'd for fit

Now take it apart and Alodine and Prime it

Jan 22, 2021 Rudder - (6.0 hours)

Category: Tail Feathers

Assembled bottom rib, attached rudder horn for final drilling (reaming) and MACH CSK. Built up all stiffeners and reamed #30 holes. deburred all holes, getting ready to dimple skins.

Rudder Horn A.jpg

IMG_2501.jpeg

IMG_2503.jpeg

IMG_2504.jpeg

IMG_2506.jpeg

Jan 17, 2021 Finishing Up Vertical Stabilizer - (8.5 hours)

Category: Tail Feathers

Finished dimpling skins and spars, machine countersinking areas. Ready for conversion coating and priming. Going to jump to rudder at this time.

Skin Dimpling

DRDT-2 works well

Finished

+ 0.007 machine countersinking

Machine CS (some burr scratches)

MACH CS

Rear Spar CS

Rear Spar CS close up

Dimpling of the ribs

Selective Dimpling

Jan 13, 2021 Vertical Stabilizer Rear Spar Day - (5 hours)

Category: Tail Feathers

Fun Day! Machine shop fun. All focus on Rear Spar, reaming, countersinking doubler, rough assemble VS sans skin.

Machine Countersink for flush Rivets

Countersink Fun!

Set-up for Countersink

AN560 Countersink

Rear Spar Doubler with CS holes

Vertical Stab Cleco'd

Jan 12, 2021 Vertical Stabilizer - (5.5 hours)

Category: Tail Feathers

Match drilled Vertical Stabilizer rear spar and assembled for final drilling 1/8 holes tomorrow.
This build incorporates the SB-00002 Dated November 5, 2020 for the RV-10
Which changes the RV-10 bottom rudder hinge bracket. New part VS-XXXX (i'll look it up tomorrow) installed.

VS-1003 Rear Spar with VS-1008 Double on top .jpeg

VS-1003 Long Shot.jpeg

Rear Spar with VS-1011 and VS-1012.jpeg

Jan 11, 2021 Rudder Stiffeners - (6.0 hours)

Category: Tail Feathers

Finished trimming, deburring and polishing up Rudder Stiffeners. Problem with a large shop is when you set down a small piece of aluminum, there are a lot of places your need to look to finally find it. Also designed tooling and jigs for new drill press and scroll saw.

Rudder Stiffeners A-G L&R.jpeg

Jan 01, 2021 Rudder Stiffeners - (3.0 hours) Category: Tail Feathers

Cutting and deburring rudder stiffeners

Dec 31, 2020 VS and Rudder - (6.0 hours) Category: Tail Feathers

No images at this time, Deburr rudder parts and begin drilling VS spar web. Happy New Year!

Dec 27, 2020 Deburring Rudder Parts - (6.0 hours)

Category: Tail Feathers

Jumped ahead to deburr rudder parts.

Rudder Horn A

Rudder Horn B.jpg

Rudder Horn C

Rudder Horn X

Rudder Horn D.jpg

R-1010 Shear Clips

R-1010 Shear Clips B

Dec 23, 2020 Short Night - (2.0 hours)

Category: Tail Feathers

Rear Spar Doubler - VS-1008 filed interior stamps and deburred all surfaces.

VS-1008 Spar Double.jpeg

VS-1008 Spar Double.jpeg

VS-1008 Spar Double.jpeg

Vertical Stabilizer Parts Deburred

Dec 22, 2020 Vertical Stabilizer - (5.0 hours)

Category: Tail Feathers

Began to debur and prep all VS parts for drilling. Slow task as I developed techniques for optimizing time required for each part.

VS Parts all deburred

Nice edge eh

Doublers

VS-1002 Front Spar, Vs-1003 Rear

Dec 31, 1969 Riveting elevator trailing edges Category: Tail Feathers

PAge 9-15 Rev 1 Step 12 continuing to rivet elevator trailing edges.