Project: RV14AWingman   -  
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Builder Name:Stefan Ballmer   -  
Project:   Vans - RV-14A
Total Hours:1079
Total Flight Time:
Start/Last Date:Apr 20, 2021 - No Finish Date
Engine:Lycoming Thunderbolt YIO-390-EXP119
Propeller:Hartzell Composite G2YR/N7605W-2X 74in
 
Friendly URL: https://eaabuilderslog.org?s=RV14AWingman

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May 07, 2024     Wing Tip Ribs - (4 hours) Category: Wings
Match-Drilled wing tip ribs using a template for the rivet spacing.
 
May 05, 2024     Wing Tip Trim - (5 hours) Category: Wings
Countersunk the archer antenna screws.
Final-fit the wing tip rear inside edges.
Sanded the tips to fit the lenses without tape.
Tightened the inaccessible screws in the antennas, and used blue locktite on the two nylon screws. Dabbed some RTV in the other screws.
 
May 02, 2024     Dual Alternator System Category: Avionics
Reply to question about an example for a Dual Alternator system.
From Dick Koehler:

Right off the top of my head, I do not have a schematic for a two alternator and two battery system. However, it is a rather simple circuit. Just design two independent alternator/battery systems and tie them together with an appropriate circuit breaker, that would be activated in the case that either system failed, so that everything (up to the load capability of the alternator) could (in an emergency) be run off of one or the other alternators. Think of a dual parallel system.
A few details. I would put one of the engine electronic ignition systems on each alternator/battery system. Ditto if you have electronic fuel injection. A common approach to all this is to use a regular alternator/battery system driven by a belt on a Lycoming, and a secondary 20 to 30 amp system off the vacuum pump drive (such as B&C). The example wiring diagram in the SAW Electricity Notebook that shows two batteries and one alternator (tiered buss architecture) could be a starting point. Just add a charging circuit to the "Engine Battery" buss (middle of pic). The logic for connecting the new "Engine Battery" buss would obviously also have to change with the addition of the second alternator.
One other thought: Trying to run two alternators at the same time on an electrical system is a bit tricky. You would need voltage regulators from a multi-engine plane that have circuitry in them that will balance the load between the two alternators. If you do not have these special voltage regulators, and run two alternators at the same time in one circuit, one will dominate and take almost all the load, while the other does little or nothing. All the small alternators that I know of that are designed to run off the vacuum pump drive do not have this paralleling feature, and so cannot be run at the same time on the same circuit of a main alternator. Hence, the idea of running independent systems, and only joining them together in the event of the failure of one system and its subsequent shutting down.
 
Apr 30, 2024     Archer Antenna Pockets - (2 hours) Category: Wings
Epoxies the pockets for Archer antennas into the wing tip.
 
Apr 26, 2024     Wing Tip Fitting - (5 hours)       Category: Wings
Coarse-fitted the wing tips to the wings. Next: drill and screw them on. After that: some fine-trimming.


 
Apr 25, 2024     Aileron Attach - (6 hours) Category: Wings
Installed the left aileron for wing tip fitting. Discovered a mistake in the QB kit: They used AN470AD4-11 instead of AN426AD4-11 for three of the rivets in the inboard aileron attachment - the rivet heads are interfering with the aileron:
https://www.vansaircraft.com/wp-content/uploads/2021/10/15_10.pdf

Also: sanded the Fiberglas to fit the lenses - getting close. Started trimming the left wing tip attachment flange.

Ordered:
AN426AD4-11
AN470AD4-11

https://vansairforce.net/threads/sb-16-03-28-come-on-vans.158010/
 
Apr 25, 2024     Primer for fiberglass       Category: Research
P-169P Prima Acrylic Urethane Primer Surfacer


 
Apr 24, 2024     Wing Tip Filling 2 - (5 hours) Category: Wings
Sanded the filled wing tips, sanded the wing tip light openings to the final fit, and filled the tips again for the remaining deficiencies.
 
Apr 20, 2024     Yup More Lens Trimming - (4 hours)       Category: Wings
More wing tip lens trimming.
Also trimmed the wing tip lens support shoulders for a better fit.
And installed the nutplates for the lens attachment screws.
And taped right lens for smooth filling.


 
Apr 17, 2024     Yes, Still More Lens Trimming - (2 hours) Category: Wings
Continues trimming the wing tip lens.
 
Apr 16, 2024     SportAir Electrical: Antenna Installation Category: Research
-Sealant for water-proofing:
*Silicone ok, but not paintable,
*Use ProSeal, or DAP (siliconized latex household caulk)

-Antenna drag
*See AC43.13-2B, page 24

-VSWR Definition:
* VSWR=|Vmax|/|Vmin|
* VSWR=(1+Gamma)/(1-Gamma)
* Gamma = (ZL-Z0)/(ZL+Z0)
where Gamma: reflection coefficient, ZL: Load impedance, Z0: cable impedance, Vmax/min: highest/lowest voltage in drive cable standing wave.
 
Apr 16, 2024     Electrical Ref G-STRV       Category: Research
Attached: G-STRV electrical ref
Page 26/27 has the wiring for a similar setup to our wings.

Reference for wing tip fitting:
https://vansrv14project.uk/wings/24-wing-tips-part-3-nav-light-covers/


 
Apr 13, 2024     SportAir Electrical AC 43.13-1B, FIGURE 11-2 Category: Research
AC 43.13-1B, FIGURE 11-2, Page 11-30
Conductor chart, continuous flow for MIL-Spec M22759 wire.

Fits:
Resistance per length:
R/L = 112uOhm/ft * 10^(AWG/10)

AWG for 0.5V voltage drop:
AWG=10*log10(4464 ft*Amp / ( I * L ) )

R: Resistance (Ohm)
L: Length (ft)
I: Current (Ampere)
AWG: American WIre Gauge of M22759 wire

Thus, the max rating (0.5V drop continuous) for each wire gauge in ft*Amp is
AWG ft*Amp
-1 5620
0 4464
1 3546
2 2817
4 1777
6 1121
8 708
10 446
12 282
14 178
16 112
18 70.8
20 44.6
22 28.2
24 17.8
For intermittent rating (1V drop), double the ft*Amps
 
Apr 13, 2024     AEROSUN VX Install - (6 hours) Category: Wings
Finished sanding the fiberglass filler.
Fitted the AEROSUN VX coarsely to the wing tips.
Epoxied the outside pivot points into the wing tips - curing now.
Some more sanding will be necessary to full light clearance.
 
Apr 08, 2024     Aersosun VX Fiberglass Work - (2 hours)       Category: Wings
Continued work on the fiberglass work for the VX lights, made 1/2 a dozen new 220/320 grit sanding blocks.


 
Apr 06, 2024     Wing Tip Inserts - (5 hours)       Category: Wings
Epoxies the new wing tip inserts for the AeroLED AEROSUN VX in place.


 
Apr 01, 2024     LDG Lens zInstale - (3 hours)       Category: Wings
Finished the edge sanding on the right LDG lens. Removed the tape on both lenses and installed them.
Started with the wing tips: marked the AeroSun VX cut-outs and cut the fiber glass. Still lots of trimming TBD.


 
Mar 31, 2024     Right LDG Lens Taping - (2 hours)       Category: Wings
Installed the right landing lens bracket tapes, and smoothed the edges of the lens. Left it installed for the tape to bond.


 
Mar 30, 2024     Right Lens Cutting - (3 hours)       Category: Wings
Cut and fitted the right landing light lens. Drilled the lens and wing in steps to #27, countersunk the lens and dimpled the wing.


 
Mar 26, 2024     Left Lens Countersink - (3 hours)       Category: Wings
Updrilled to #27 and ountersunk the left landing light lens. Dimpled the left wing for the lens. Deburred everything. Taped the two brackets.


 
Mar 22, 2024     LDG Light Lens Cutting - (4 hours)       Category: Wings
Section 17, Page 17-09, Step 1 to Fitted and drilled the left landing light lens. Countersinking, dimpling and radiusing the edge still TBD.


 
Mar 21, 2024     Landing light lens work - (3 hours) Category: Wings
Drilled out and fixed one bad AN426AD3-3.5 rivet in the left top skin.
Marked up the landing light lenses for trimming.
 
Mar 18, 2024     Fairing Riveting - (3 hours)       Category: Wings
Section 20, Page 20-02, Step 5: Complete: Clecoed the W-00010-L and W-00010-R Flap Gap Fairing and W-00011-L and W-00011-R Aileron Gap Fairing to the top skins and Rear Spar Assembly. Riveted the gap fairings to the Rear Spar Assembly and the top skins. We used AN426AD4-8 (6x) instead of the CherryMax for the six innermost rivets (i.e as recommended for the slow-build). For the remaining 1/8in rivets we only used the MSP-42 (14x each wing) where existing skins made it impossible to use AN470AD4-4 or AN470AD4-5.


 
Mar 17, 2024     Flap Gap Riveting - (7 hours)       Category: Wings
After a thorough shop cleaning we started installing the Flap Gap Covers:

Section 20, Page 20-02, Step 4: Complete: Clecoed then rivet the W-1021B-L Flap Gap Stiffener to the W-00010-L Flap Gap Fairing. Same for W-1021B-R and W-00010-R.
Section 20, Page 20-02, Step 5: Clecoed the W-00010-L Flap Gap Fairing and W-00011-L Aileron Gap Fairing to the top skins and Rear Spar Assembly. We used AN426AD4-8 (6x) instead of the CherryMax for the six innermost rivets (i.e as recommended for the slow-build). For the remaining 1/8in rivets we only used the MSP-42 where existing skins made it impossible to use AN470AD4-4 or AN470AD4-5. Riveted the W-00011-L gap fairings to the Rear Spar Assembly. Remaining gap fairings TBD.

One AN426AD3-3.5 river cracked and will have to be drilled out.


 
Mar 16, 2024     Control Hardware Priming - (12 hours)       Category: Fuselage
Finished the Pitot Probe Installation: Flared the Pitot line.

Section 56, Page 56-02, Step 1: Complete: Fabricated two servo pushrod tubes from AT6-058X5/16 aluminum tube for pushrod assemblies CS-00017 and CS-00019.
Section 56, Page 56-02, Step 4: Complete: Fabricate one CS-00020 Roll Servo Standoff from AT6-058X5/16 aluminum tube.

Also fixed the Halogen lamp.

Priming:
======

Sprayed the following parts with Sherwin-Williams P60G2 Wash Primer:
GMU-22 Mounting Ring
F-1097 Spacers (4x)

Sprayed the following parts with AkzoNobel Primer:
BUSH AL.197X. 313X.438 (2x) in BAG 1218-2
BUSH AL.197X.313X.594 (2x) in BAG 1218-2
BUSH AL.197X313X1.075 (2x) in BAG 3104
Servo Pushrod Tubes (2x) for CS-00017 and CS-00019
CS-000 20 Roll Servo Standoff

Primed the interior of the following control rods / tubes / hardware with AkzoNobel Primer:
CS-00007-L-PC Control Stick Base, Left
CS-00007-R-PC Control Stick Base, Right
CS-00008T-PC Control Stick (2x)
CS-00010 Flap Torque Arm (2x)
WD-1013A Flap Crank
WD-655-L Rudder Pedal Left
WD-655-R Rudder Pedal Right

This leaves the CS-00006 Control Column as only steel part that we haven't primed with the AkzoNobel - that's because it is already installed in the QB Fuse. We will likely have to spray in some rattle-can primer (SEM 39693 Green Self Etching Primer).


 
Mar 15, 2024     Riveting Pedals - (8 hours)       Category: Fuselage
Finished the Rudder Pedals:
Section 33, Page 33-03, Step 1: Complete: Fabricated four F-1097 Spacers from AT6-058X5/16 6061-T6 aluminum tubing.
Section 33, Page 33-03, Step 7: Complete: Clecod, then riveted the CS-00018A Brake Pedal Pads, CS-00018B Brake Pedal C-Channels, and F-1052B Brake Pedal Side Plates.
Section 33, Page 33-03, Step 8: Complete: Clecod, then riveted the CS-00018C Brake Pedal Z-Channels.

Pitot plumbing:
Riveted the Pitot Fitting Bracket and AOA Fitting Doubler to the rib.
Installed the AOA Fitting (Permatex #2 on the fitting, some Dow Corning RTV 3145 Gray for damping between fitting and bracket.
Bent and cut the GAP 20 pitot probe tubes. Flared the AOA line.

Also Prepared the GMU-22 mount ring for priming.


 
Mar 05, 2024     ACBD - (5 hours)       Category: Wings
Finished the aileron torque tubes. Need to do a better job labeling parts, particular when handing off to someone else.
Started assembling the aileron push tubes.
Installed the pitot fitting to the custom fitting bracket: used Permatex #2 for the hose fitting, and Dow Corning RTV 3145 Gray for damping between fitting and bracket.



 
Mar 03, 2024     Prime Sunday - (6 hours)       Category: Wings
Primed the remaining aileron torque tubes and Elevator push rods.
Section 23, Page 23-07, Step 4: Assembled the front and back subassemblies for the aileron torque tubes, installed the AN3-13A bolts, plus NAS1149F0332P washers, plus MS21042-3 nuts.

The measured friction torque for the MS21042-3 to be 10in-lb. Vans sais they measured 14in-lb, but results can vary (section 5). We split the difference and went with 12in-lb. Plus the 28in-lb torque spec for these nuts:

We torqued to 40in-lb and torque-sealed them.


 
Mar 02, 2024     Pitot Bracket Design and Prime - (6 hours)       Category: Wings
Primed aileron push rods torque tubes and pitot brackets.
Attached are the design sketches for the pitot bracket and douler.


 
Feb 27, 2024     AOA Doubler       Category: Wings
We decided to go with the pitot fitting bracket, and also made a doubler plate for the AOA fitting.
Might still add a lightening hole for the doubler. Or might not. Otherwise ready to prime airleron torque tube and pitot fitting brakets. (Booth is ready.)


 
Feb 25, 2024     Tube Spacer and Fitting Bracket - (6 hours)       Category: Wings
Section 23, Page 23-07, Step 1: Manufactured the 1 1/64 in spacer block for the Aileron Torque Tube alignment.
Section 19, Page 19-04, Pitot Install: Designed and manufactured a 60deg tube fitting bracket for the pitot static line. The bracket mounts on the wing rip like a tripod on the rib's flat areas, and provides support for the fitting at a 60deg angle, angled towards where the pitot static line comes from the Garmin pitot tube.

Also verified that the controller box of the GAP-20 regulated heated pitot tube has no direct connection between ground and chassis.


 
Feb 18, 2024     Torque Tube Cutting - (4 hours)       Category: Wings
Section 23, Page 23-06, Step 3: Complete: Fabricated two CS-00009B Torque Tube Collars by cutting WD-1014PC into two 7 5/16 inches long pieces.
Measured 1 1/2 inches from one end of each torque tube collar. Inserted the CS-00009B Torque Tube Collars in to the open ends of the CS-00009 Torque Tube Subassemblies. Match-Drilled #30 the torque tube collar using the holes in the Torque Tube Subassemblies as drill guides. Final-Drilled #12 through both sides of the Torque Tube Subassembly and torque tube collar.
Section 23, Page 23-06, Step 4: Marked the CS-00009 Torque Tube Subassemblies and CS-00009B Torque Tube Collars so that they can be re-installed in the same orientation as when they were match-drilled. Deburred the holes. Final-Drill #12 the .188 in [4.8 mm] holes in the arm of each torque tube subassembly.

Next: Prime!


 
Feb 17, 2024     Pitot Routing - (3 hours)       Category: Wings
Looked at options for pitot tube hose routing.
We have two options for the 3/16 aluminum tube to 1/4 in nylon:
* 1/4″ to 3/16 push adapter:
https://www.steinair.com/product/fitting-straight-pitot-union-connector-1-4-to-3-16-adapter/
* P-AN819-3D, P-AN818-3D, P-AN816-3D, P-515 (we actually have this al part of the pitot static kit):
https://www.steinair.com/product/an816-3d-nipple/

I like the 2nd one better, but it is heavier and will need some form of bracket for support. An example bracket is attached as picture.


 
Feb 11, 2024     Pitot Nut Plates - (1 hour)       Category: Wings
Installed nut plates for pitot base.


 
Feb 10, 2024     Priming Pitot Bracket - (4 hours)       Category: Wings
Cut the GMU-22 mounting kit pieces into shape.
Primed the Pitot bracket and GMU-22 mounting hardware.
Started priming the aileron actuation rods.


 
Feb 08, 2024     Pitot Countersinking - (2 hours)       Category: Wings
Countersunk the Garmin Pitot Tube Bracket. Now 4x MS24693S24 can be used to mount the pitot tube.
Patched one pitot bracket mounting hole on the rib with JB-Weld. (It was drilled oval by accident.)
Dremeled the front of the oval hole in skin+bracket to properly fit the pitot tube mount.

The Hardware needed for mounting the pitot tube is:
4x MS24693-S24 (632 flush head, 1/4in) for mounting pitot tube to pitot tube stem.

2x NAS1801-08-12 (832 hex screw, 3/4in) for mounting pitot tube stem to pitot tube base.
2x AN365-832A (MS21044N08) elastic stop nuts for mounting pitot tube stem to pitot tube base.
6x AN960-8L washers, two of them slimmed to 0.01in, for mounting pitot tube stem to pitot tube base.

4x MS24693-S50 (832 flush head, 1/2in) for mounting pitot tube base to pitot tube bracket and skin.

4x MS24693-S28 (632 flush head, 1/2in) for mounting pitot control box to pitot tube bracket and skin.


 
Feb 03, 2024     Pitot mounted to Rib       Category: Wings
Continued Aileron control rod and pito bracket mounting work.
Cut the pitot opening into the left bottom skin. Drilled lightening holed to the pitot bracket. Cut the angle for mounting the pitot bracket to the rib. Match-drilled the angle to the rip and pitot bracket.

Still TBD:
- Drill up one rivet hole in bracket that is interfering with the Garmin mount.
- Dremel up the front of the pitot cutout to make it fit the pitot arm.
- Countersink the 4 screws in the pitot arm.

Also: received Garmin AP servos, ADAHRS, temperature sensor, magnetometer and VOR antennas, pictures attached.


 
 
Jan 30, 2024     Pitot Countersink and Aileron Bellcranks - (5 hours) Category: Wings
Continued Aileron actuation work.
Continued Pitot adapter plate: countersinking, drilling skin, dimpling, etc.
 
Jan 30, 2024     CS-00013 Aileron Pushrods - (2 hours)       Category: Wings
Section 23, Page 23-04, Step 2: Complete: Drilled #40 the four pilot holes in each end of both CS-00013 Bellcrank to Aileron Pushrods. Deburred the holes in the bellcrank to aileron pushrods.
Section 23, Page 23-04, Step 3: Match-Drilled #30 the threaded rod end using the pilot holes in the bellcrank to aileron pushrod as drill guides. Inserted clecos in the holes as match-drilling progresses. Repeat until threaded rod ends have been match-drilled to both ends of the bellcrank to aileron pushrods. Marked the threaded rod ends so that they can be re-installed in the same position as when they were match-drilled. Removed the threaded rod ends from the bellcrank to aileron pushrods and deburr the holes.


 
Jan 25, 2024     Pitot and Aileron Work - (4 hours)       Category: Workshop
Continued manufacturing the pitot attach plate for the Garmin Pitot mount.
Continued drilling the aileron actuation rods.


 
Jan 23, 2024     Pitot Mounting - (5 hours)       Category: Wings
Section 23, Page 23-03, Step 1: Started fabricating two CS-00012 Torque Tube to Bellcrank Pushrods by cutting two pieces of
AT6-035 X 1 1/8 to the length (64 1/4 in).
Used Permatex Form-a-Gasket No.2 to install the VA-261 (Fuel Strainers) and AN913-3D (plug).
Started manufacturing the pitot mount doubler. The design idea is attached in pictures - although it is not completely to scale.


 
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