Project: bhoward   -  
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Builder Name:Brian Howard   -  
Project:   Vans - RV-7A   -   VIEW REPORTS
Total Hours:322
Total Flight Time:
Total Expense:$11440.00
Start/Last Date:Oct 27, 2021 - No Finish Date
 
Friendly URL: https://eaabuilderslog.org?s=bhoward

Home or Last Project Picture

Jul 03, 2022     Finished last rivets on the rudder - (1 hour)       Category: Empennage
The really tight rivets near the trailing edge took some time to set. Only had to use a pulled rivet on the final rivet on both sides (nearest the trailing edge). Used a home made bucking bar to get the next 2-3 rivets on the bottom and top.

DONE!

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Jun 19, 2022     Actually riveted the leading edge - (2 hours) Category: Empennage
After working the leading edge a bit more, final rivet set. (Lower section finally completed.)
 
May 25, 2022     More rolling on the leading edge Category: Empennage
Just documenting the hours - previous post has detail.
 
May 24, 2022     Rolled the leading edge - (6 hours) Category: Empennage
I HATE rolling the leading edges. But even worse was the lower section of the rudder. That sucker is TIGHT if you don't do it right. It took several tries to get the two sheets of 2024 to meet without a lot of pulling. After hours of working the roll, I finally got the bend somewhat close to the profile view on the plans and the rivets were easy to set.
 
May 19, 2022     Riveting the trailing edge. - (2 hours) Category: Empennage
 
Apr 30, 2022     Record keeping - (2 hours)       Category: Empennage
Updated this site from notes on the plans I take while building. Attached are images of the plans and dates. Getting worried about damaging the notes as there is already water damage due to other work happening in my shop.

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Apr 30, 2022     Set a few rivets - (1 hour)       Category: Empennage
Waiting on sealant and a better flush rivet set. Set what could be squeezed and pulled a few blind rivets. Also sizing the alignment to the vert stab.

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Apr 27, 2022     Riveted the counterbalance rib and skin - (2 hours) Category: Empennage
Also clecoed the skins
 
Apr 23, 2022     Finished the rudder skeleton. - (2 hours) Category: Empennage
 
Apr 20, 2022     Started building rudder skeleton - (2 hours) Category: Empennage
 
Apr 19, 2022     Rudder trailing edge prep - (2 hours) Category: Empennage
Countersunk R-916. Then primed. (Twice as I forgot to prep and the primer essentially fell off. Scotchbrite and paint thinner to prep. Then primed.)
 
Apr 16, 2022     Started building the rudder - (6 hours) Category: Empennage
Stopped building after a business trip. Also received an update on when the wings might ship: august- ugh. No need to rush and not interested in re-rebuilding the rudder.

Finished, deburred and dimpled.

 
Mar 17, 2022     Installed stiffeners - (3 hours) Category: Empennage
Dimpled stiffeners and skin. Riveted stiffeners (back riveted and 3M masking tape works very well!)
 
Mar 16, 2022     Match drilled stiffeners… slowly - (3 hours) Category: Empennage
 
Mar 13, 2022     Finished stiffeners - (2 hours) Category: Empennage
 
Mar 12, 2022     Rudder stiffeners #2 - (2 hours) Category: Empennage
After damaging one of the skins (R-901-R) I received a new one from VAns wit stiffeners and more rivets. Today began breaking the stiffeners apart.
 
Mar 11, 2022     Trim cover plate - (8 hours)       Category: Empennage
Well this one step took at least 8 hours over several weeks of frustration!

Alignment of the motor to properly access the trim tab without taking out metal from the elevator skin OR bending the pushrod was the goal.

First try was accomplished after measuring and then remeasuring the assembled tab. Drilled and riveted. Nope. Pushrod would rub the skin.

Formed a new cover from scrap aluminum. Easy enough. With a cardboard model of the motor and pushrod I remeasured everything. Drilled and assembled. Nope. Ugh.

Formed a third cover. Repeat with all lessons learned. Riveted everything together. NAILED IT.

A month later I had the chance to view an RV7a that has been flying for years. Yea, I did better! But what a pain…

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Mar 10, 2022     Removed flange on h stab - (3 hours) Category: Empennage
Tedious job.
- installed elevator
- measure and mark
- remove elevator
- trim metal
- install elevator
- ugh- repeat

And then repeat for left elevator..
 
Mar 06, 2022     Installed rod end bearings - (4 hours) Category: Empennage
That was frustrating! (Hitting the hole while aligning everything while standing on one foot.

That was fun! That is- seeing something looking like a functional airplane assembly!
 
Mar 05, 2022     Rolled leading edge - (5 hours) Category: Empennage
Well, looks mostly correct. I feel like I should do a practice elevator before doing the final product :(

But, it is just cosmetic. Pulled the leading edge causing a little bending near the spar. Not much and appears I'm not the only one. Most of the roll looks pretty good though.
 
Mar 03, 2022     Finished trim tab - (1 hour) Category: Empennage
Set blind rivets and hinge pin.
 
Feb 26, 2022     Riveted the tab and installed - (5 hours)       Category: Empennage
Assembled and riveted the tab. Riveted the hinge to the elevator.

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Feb 25, 2022     Finished prepping the tab - (2 hours) Category: Empennage
Trim, finish, deburr, dimple .. oh my…
 
Feb 24, 2022     Drilled the tab spar - (2 hours) Category: Empennage
 
Feb 22, 2022     Continuing trim tab - (2 hours) Category: Empennage
Bent the tabs. Drilled the tab horn.
 
Feb 21, 2022     Completed the trailing edge bend on the trim tab - (1 hour) Category: Empennage
 
Feb 13, 2022     Riveted the left elevator - (5 hours) Category: Empennage
Completed the left elevator. Still need to do the trim motor and tab.
 
Feb 10, 2022     Riveted the counter balance skin - (1 hour) Category: Empennage
Just a little work today.
 
Feb 08, 2022     Riveted the elevator skeleton - (2 hours) Category: Empennage
 
Feb 07, 2022     Bender the elevator tabs. - (2 hours) Category: Empennage
Well, it turned out ok, but could have been a little better if I would have left well enough alone. Once the blocks are removed- stop hammering the metal! It is a little less than straight, but I may be the only one that notices….
 
Feb 05, 2022     Preparing the trim spar - (2 hours) Category: Empennage
 
Feb 01, 2022     Deburred and dimpled the left elevator - (4 hours) Category: Empennage
 
Jan 28, 2022     Finished drilling the left elevator - (5 hours) Category: Empennage
 
Jan 27, 2022     Completed the right elevator - (2 hours)       Category: Empennage

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Jan 26, 2022     Riveted the skeleton together. - (2 hours) Category: Empennage
 
Jan 25, 2022     Finished left elevator prep - (1 hour) Category: Empennage
 
Jan 24, 2022     E709 prep- left elevator - (1 hour) Category: Empennage
 
Jan 21, 2022     Left elevator prep - (2 hours) Category: Empennage
I started the elevator build by performing the same steps on left and right elevators. Today the focus is on the right elevator skeleton.
 
Jan 20, 2022     Drilling counter balance for elevators - (3 hours) Category: Empennage
This includes the rib and the lead weights. Using a little oil did seem to help the bit not gum up.
 
Jan 19, 2022     Working doublers and reinforcing plates - (2 hours) Category: Empennage
Continuing work but easy compared tot he trailing edge.
 
Jan 19, 2022     Bent trailing edge of the elevators - that was a “job” - (3 hours) Category: Empennage
Anyone else doing this step- go slow. Easy to get odd shapes on the trailing edge near the stiffeners. With some work one can make it look better ….
 
Jan 17, 2022     Drilled and back riveted stiffeners - (3 hours) Category: Empennage
 
Jan 14, 2022     Finished stiffeners - (2 hours) Category: Empennage
 
Jan 13, 2022     Started elevator - began building the stiffeners - (2 hours) Category: Empennage
 
 
Jan 07, 2022     Riveted the vert stab skeleton - (2 hours) Category: Empennage
 
Jan 06, 2022     Clecoed the vertical stab skeleton - (1 hour) Category: Empennage
 
Jan 05, 2022     Finalized drilling vertical stab - (2 hours) Category: Empennage
 
Jan 04, 2022     Drilled the vertical stab skin - (2 hours) Category: Empennage
 
Jan 03, 2022     Continuing the vertical stab skeleton - (2 hours) Category: Empennage
 
Dec 31, 2021     Building the rudder skeleton - (8 hours) Category: Empennage
Back riveting was fun! But messed up when I didn't have the plate properly place once. Just a cosmetic dent. I'll have someone take a look, but looks better than hangar rash on some I've seen. But this is a control surface, so I'll get that second set of eyes.

Also started building the rudder skeleton. Lots of pieces coming together.
 
Dec 30, 2021     Fitting the Stiffeners to the Rudder skin - (2 hours) Category: Empennage
Deburred and dimpled the rudder skins.
 
Dec 29, 2021     Fitting the Stiffeners to the Rudder skin - (2 hours) Category: Empennage
Drilled all the stiffeners
 
Dec 23, 2021     Fitting the Stiffeners to the Rudder skin - (2 hours) Category: Empennage
Sized the stiffeners to match the skins per plan.
 
Dec 22, 2021     Drilling the V Stab - (4 hours) Category: Empennage
Mostly match drilling the spar - and then spent a fair amount of time realizing I really was sent 3 HS-706 tip ribs and zero VS-706 tip ribs. Will call Vans to get a part sent. I was hoping it was just the same part, but not the case - different dimensions.
 
Dec 19, 2021     Drilling the V Stab - (2 hours) Category: Empennage
Mostly identifying parts, pulling blue plastic and clecoing everything together.
 
Dec 17, 2021     Riveting the H Stab - (2 hours)       Category: Empennage
First real go at blind rivets. Easy enough - but getting them in place was not much fun.

And the first part is done!!

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Dec 15, 2021     Riveting the H Stab - (2 hours) Category: Empennage
Finished the right side and riveted on the rear spar - up-side-down. Grrr... well, I must have things pretty square as it went on easily! Oh, well, symmetric part an only the "up" arrow I drew now points "down".
 
Dec 14, 2021     Riveting the H Stab - (3 hours) Category: Empennage
Got most of the right side done - a little easier with the PC on the skin trick.
 
Dec 12, 2021     Riveting the H Stab - (6 hours) Category: Empennage
Well, that was VERY FRUSTRATING getting the first few rivets on the middle rib - flush and ... required several tries. Even had to drill out the first go at it. The final solution was to take and old PC and lay it on top of the skin to keep it from pulling the first rivet out as I was working the second one.... but I got all the rivets in - and the rib flange is flush against the skin. The process was not fun, but the result looks a little like part of an airplane! Won't be the prettiest, but looks a lot better than some of the airplanes I've rented.

Left side riveted!
 
Dec 08, 2021     Riveting the H stab - (2 hours) Category: Empennage
Got more TV watching then riveting, but did get a few ribs riveted.
 
Dec 07, 2021     Riveting the H Stab - (2 hours) Category: Empennage
Riveted the front spar together.
 
Dec 04, 2021     Riveting the H Stab - (2 hours) Category: Empennage
Just got the hinge brackets together. I will need to buy a small torque wrench as the one I have is too big for these small bolts.
 
Dec 01, 2021     Riveting the H-Stab - (3 hours) Category: Empennage
Riveted the rear spar parts together. Got a couple of "smilies", but nothing terrible. I gotta remember to clam everything down as that aluminum moves around with the rivet gun going!
 
Nov 30, 2021     Preparing parts for assembly - (6 hours) Category: Empennage
More time was spent over the week finishing, deburring, and dimpling. Not sure all the time was tracked. Kind of a turn on the TV and pick a part to work on. Also primed the non alclad parts. HS-609, HS-710, and HS-714. Two coats of self etching primer, black.
 
Nov 16, 2021     Drilling the H Stab - (2 hours) Category: Empennage
Completed drilling the right side of the H stab!
 
Nov 15, 2021     Drilling the H stab - (2 hours) Category: Empennage
Finished the left side and started the right side.
 
Nov 14, 2021     Drilling the H Stab - (4 hours)       Category: Empennage
Many steps on the left side of the H stab - fitted and drilled all the ribs. CLECOs look cool once in place.

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Nov 13, 2021     Drilling h stab - (6 hours) Category: Empennage
This was a lot of fun - actually mating a skin to the frame to fit all the ribs in place. Actually looking like something "aircraft like".
 
Nov 12, 2021     Preparing ribs - (2 hours) Category: Empennage
Most of the ribs were nearly perfect - but not quite. Very little fluting was needed but did use a pair of needle nosed pliers to get each flange perpendicular to the rest of the rib.
 
Nov 10, 2021     HS-411 assembly - (2 hours) Category: Empennage
Waited to get some primer before starting on the VA-146. I'm guessing it isn't pure aluminum. Primed and riveted together the assembly.
 
Nov 07, 2021     Preparing ribs - (3 hours) Category: Empennage
Dimple and countersink for the flush rivets holing the front spar together. Odd, but Im guessing something goes here later that needs more clearance.

Notched rib to fit around the spar.
 
Nov 04, 2021     Match drilling - (1 hour) Category: Empennage
Match drilling ribs for H stab
 
Nov 03, 2021     HS710 - (2 hours) Category: Empennage
Tapering ends of the HS710.
 
Nov 02, 2021     Match Drill Doublers - (1 hour) Category: Empennage
Match drilling spar doublers -
 
Nov 01, 2021     Front Spar - (1 hour) Category: Empennage
Bending down tab as specified in plans. Not a lot of work - but keeping momentum.
 
Oct 31, 2021     Front Spar - (4 hours) Category: Empennage
Match drilling the front spar for the H stab
 
Oct 30, 2021     Elevator hinge brackets - (2 hours) Category: Empennage
Continuing the build with 2 hours most nights. Completed the elevator hing bracket match drilling.
 
Oct 28, 2021     Prepared HS-609PP - (2 hours)       Category: Empennage
Using scotchbrite wheel, cleaned up the reinforcing bar per plans. Then clieco'd the bar to the rear spar and match drilled using #30 drill bit per plans.

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Oct 27, 2021     Prepare HS-609PP - (2 hours) Category: Empennage
Following first instruction to prepare the reinforcing bar HS-609PP.
- Numbered each item for (re)placement as items are worked
- used scotchbrite wheel to prepare the edges
- ends rounded to 1/4 inch
- worked edges of bar to lay flat near HS-603PP - per instructions.

Aluminum dust! Will get PPE...

 
Oct 26, 2021     Received and inventoried - (2 hours)       Category: Empennage
Empennage arrived, unpacked and inventoried.
- One rib missing VS-706
- One extra rib HS-706
- One bearing missing MD3616M

Also looks like the label are a little different in the BAG 616-PC sub-kit. looks like the correct parts, but the labels are different than what is on the documentation (e.g. HS-411BPP-PC is labeled as HS-411PPC)

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