Aug 11, 2022     15-3 & 15-5: Right aileron bracket - (1.2 hours)       Category: 15: Rear Spar

Finally got around to finishing the redo of the aileron bracket. I had received a new part from Vans back in June, but accidentally countersunk the incorrect holes. Ordered another bracket. That part came in a while back but has just been sitting. Finally got it primed and assembled. Easy-peasy. This is done now.

  May 15, 2022     15-2 thru 15-3 & 15-5: Right rear spar assembly - (1.8 hours)       Category: 15: Rear Spar

Started assembly of the right rear spar. Got the aileron brackets squeezed and cleco'd everything to the wing assembly.

Installing rivets in the aileron bracket was a challenge. First couple didn't set flush because of the rivet set riding up the filet of the angle. Drilled out and redid them, but then the -11 rivet was not long enough. Ended up with a good flush head but ended up with an inadequate shop head. Ordered some -12 rivets to redo.

Riveted the ribs to the rear spar and realized it would be good to have the Longeron yoke for the squeezer. I don't know how I got these with the squeezer on the left wing; ended up bucking most of the rivets on this wing. I've been putting off that purchase for a while; time to give in.

5/16 - finished the inboard doubler rivets before work.

5/17 - drilled out the -11s in the aileron bracket. The holes a pretty wallowed out. I opted to fabricate a new bracket with fresh holes. Just happened to have a short piece of .125 x 3/4 x 3/4 angle stock that fits. Used old bracket to match drill holes to the rear spar. Then clamped to bracket assembly and match drilled bracket holes. Everything came out good. Ready to prime and re-rivet.

5/21 - looking more closely at the other angle of the aileron brackets, I'm not 100% happy with them. The countersinks were hiding a bit of the hole damage. I think if I replace both angles on either side of the brackets, it will be more secure. Trouble is, I don't have any more angle stock to replace the longer piece - I'll just order the W-1013F/G replacement from Van's and that will give me new match drilled parts for both sides. It's not in my critical path for assembly - might as well replace it.

Purchases: ACS - AD426-4-12 rivets. Cleveland - 1/2” flush set, rivet tape, Longeron yoke. Van's - replacement W-1013F/G and assorted snap bushings.

  May 13, 2022     15-5: Right rear spar - (2.0 hours)       Category: 15: Rear Spar

Cleco'd the rear spar in place and countersunk the few holes that had to done. Match drilled the holes at the doubler plates. Final pass with a scotchbrite pad to deburr everything. Ready to prime if it cools off.

5/14 - got everything primed. Ready to assemble. No photos. Missing rib showed up today to so I guess I'll prime that tomorrow and install.

  May 07, 2022     15-4: Right rear spar work - (1.0 hour)       Category: 15: Rear Spar

Started progressing the rear spar. Match drilled all of the doublers and cut out the large hole for the aileron linkage.

  Apr 26, 2022     15-4: Left rear spar assembly - (2.6 hours)       Category: 15: Rear Spar

Dimpled the spar bottom flange and 26 inboard top flange holes, cleco'd everything in place for riveting. Trying to make sure which way the rivets go - for most the spar is the thicker material, so shop heads should be on the outside. Shop heads on the inside would be more aesthetically pleasing. Quick search of other builders blogs seems to show shop heads on the inside. That would be consistent with how I did the HS too.

Riveted the spar with various sizes called out in the plans. Was able to squeeze most but had to buck a few awkward ones, particularly near the root. Bucking gun was fine except one that the gun jumped and obliterated the rivet head. Had a very hard time drilling it out and tore up the hole a bit. Tried to save but went with another AN bolt. Just one of several in that field of rivets at the rear attach doubler. Biggest problem is that it is not easy to inspect.

5/4 update: back-ordered bearing arrived so was able to complete the aileron bracket assembly and rivet to rear spar. I used just some rubbing alcohol to remove some tape residue from the rivet heads and was very disappointed to see some of the primer come off. Will need to really consider the EkoPoxy for the fuselage priming.

  Apr 24, 2022     15-2 thru 15-4: Left rear spar - (4.5 hours)       Category: 15: Rear Spar

Did all the fabrication of the aileron attach brackets for both the left and right wing.

Match drilled the doublers and cut the hole in the one for the aileron pushrod. Traced the hole against the rear spar, drilled a couple starter holes with the unibit and then finished it off with sanding drums on the deemed.

Got everything cleco'd to the wing ribs. Was a little unsure about the W-00007C and D brackets but got some answers from RV-10 Facebook group.

Finished up with countersinks in a few places. Almost missed the countersinks in W-1013F but someone on FB responding to my other question pointed it out. Dimpled the rear tab of the ribs. Should have dimpled these before attached flap brackets.

Ready to prime.

4/25: snuck in some priming after work.