Apr 29, 2024     Made and installed new bellcrank brackets on R wing - (4 hours)       Category: Wings

Made installed new bellcrank brackets of the proper thickness.

  Mar 09, 2024     Removed incorrect bellcrank mount - (2.5 hours) Category: Wings

Removed incorrect 0.063" thick bellcrank mount angle from R wing.

  Mar 09, 2024     RV-Ator - (3 hours) Category: Research

I was given a copy of an old synopsis of the RV-Ator 1980-1997.
This was very useful.

I learned of the MIL-R-46196(MI) riveting standard, and there a mention of a common error where builders used 0.063" angle instead of the required 0.125" for the aileron bellcrank bracket. Sure enough, the previous builder used 0.063" on my right wing.

  Mar 03, 2024     Finished removing top skin rivets - (2 hours) Category: Wings

Finished drilling and removing the remains of the rivets for the top skin.

  Mar 02, 2024     Received Finish Kit - (3 hours)       Category: Fuselage

Finally received the finish kit from Van's after more than 2 years of waiting and a massive price increase.

  Mar 02, 2024     Assembled some “free” shelves! - (3 hours)       Category: Workshop

  Feb 17, 2024     Removed outboard R wing top skin - (4 hours)       Category: Wings

I removed the R wing outboard skin due to poor riveting by the previous builder. This will allow me to more easily fully inspect the rest of the wing.

  Feb 11, 2024     Removed inner R wing top skin - (6 hours)       Category: Wings

Made the decision to remove the wing top skins to inspect the wing more thoroughly, and replace the many improperly set rivets that I found on initial inspection.

Removed inboard right wing top skin.

  Jan 28, 2024     Inspect fuselage rivet quality, study plans and build manual - (3 hours) Category: Fuselage

Inspected fuselage rivet quality, marked any defects with blue tape.
Studied build manual and plans for fuselage.

  Jan 21, 2024     Inspected right wing - (6 hours)       Category: Wings

Inspected right wing using a borescope, checking rivet quality. Noted several deficiencies.

  Jan 21, 2024     Received partial firewall forward kit - (2 hours)       Category: General

Received partial firewall forward kit.
Some parts were on backorder, including the exhaust system.
Two parts were missing, one washer, and a heat shield.

  Jan 01, 2024     Remove Aileron, Flap, and Fuel tank from Right Wing - (2.5 hours)       Category: Wings

Removed the Aileron, Flap, and fuel tank from the right wing. This is so I can inspect the wing carefully, and verify it is built to the plans.

  Dec 31, 2023     Removed Flap Lever - (2 hours)       Category: Controls

The previous builder had modified the flap lever in an effort to DIY electric flaps.

I removed this lever and will replace with a new lever weldment from Van's.

  Dec 31, 2023     Moved project to a hangar - (6 hours)       Category: General

Moved the aircraft to a hangar!

  May 15, 2022     Joined EAA Chapter 292 Category: General

I Joined EAA chapter 292 in Independence Oregon. It appears that there a lot of fantastic people there that will be great resources as I build this airplane.

Their website is here:
https://www.eaa292.org/

  May 04, 2022     Getting back into it. Ordered new front deck piece - (2 hours) Category: General

Now that I have some available time, and my move is mostly complete, I'm getting back into working on the plane. I ordered a replacement fuselage forward top deck piece from Van's. One mistake I made was simply looking at the plans and picking out the part I thought I needed. It turns out that that piece is different if you are planning on using the sliding canopy, which I am. The sliding canopy modifications are not in the main portion of the plans, but in a separate section.

At first I thought I could just order a piece from Alaska Copper and Brass, but they don't carry that alloy and were surprisingly rude about it when I asked. Weird.

I just had a birthday! My wife got a dipstick for my O-320! It was a part my engine didn't have, and it's great to get that port sealed up properly.

  Apr 10, 2022     Moved airplane to new house - (6 hours)       Category: General

Moved the airplane from my old house to the new house.

  Jan 30, 2022     Updates! - (3 hours)       Category: General

Hello!

I apologize for the lack of updates for the last few weeks! I've been doing a timelapse photography project in my garage, and working on the airplane would have affected the lighting. That project is finished, but I'm still likely to make little progress for the next month or so since I bought a house and will be moving!

In the meantime I built a Van's toolbox training kit and learned the basics of riveting. I also made an error in the assembly. Maybe you can spot it :)

  Dec 25, 2021     Found some ebay deals on a couple parts. - (1 hour) Category: Avionics

I found a couple eBay deals. Snagged a UMA tachometer that should match with the Plasma II+ ignition, and a PMA6000M audio panel.

I chose the PMA6000 since it has the built-in intercom. I also made the decision to go with a combination of steam gauges and G5(s) or similar for now. I already have many of the parts and pieces, and I can always upgrade to a G3X or something at a later time.

  Dec 25, 2021     Changed desiccant, found missing case bolt. - (.5 hour) Category: Engine

I changed the desiccant plugs on the engine today since the front two had started turning pink. When I was looking over the engine, I found a missing case bolt near the alternator bracket. It was probably removed when the alternator was installed. It's just a normal looking 1/4"-20 bolt and nut, but I'll see if I can find the correct Lycoming part for it.

  Dec 25, 2021     Inspected left wing. - (2 hours)       Category: Wings

I removed the clecoed in place covering on the left wing and inspected the work underneath. I found a few obviously defective rivets, and a few that I need to put a rivet gage on. I also found a small crack in a dimple for the wingtip screws. I'm glad I did this inspection, but I'm a little worried I may not like what I find in the other wing once I borescope it. I'm worried I may have to do a lot of drilling!

  Dec 25, 2021     Front deck - (2 hours)       Category: Fuselage

I removed the 2024-T3 deck and installed the 6061-T6 deck. It does seem that the 6061 deck does fit a bit better, but it's got a tiny bit of surface corrosion and just looks dull. It also seems to be a bit softer. I need to reach out to some experts and make a decision of which one to use.

One big issue with the 2024-T3 deck is the rivet holes are countersunk. They are dimpled on the 6061 deck, and because of this, the framework underneath is also dimpled. I have a feeling that countersinks over dimples isn't the best idea.

  Dec 25, 2021     Christmas time shopping! - (4 hours)       Category: Tools

After finding out what gifts I received for Christmas, I decided to purchase some outstanding tools.
A few clecos I didn't have, a borescope, deburring tool, palm drill, and a few other minor things were on the list.

For Christmas: I got a rivet cutter, a rivet drilling guide, and a gats bottle.

  Dec 17, 2021     Identified sheet metal components, assembled forward deck - (3 hours)       Category: Fuselage

Identified the sheet metal components that were laying loose in the bottom of the fuselage. Assembled the forward deck and the structure.
There were two deck coverings, one made of 6061-T6, and the other made of 2024 alclad. I believe the 2024 was the original piece shipped with the kit, the 6061 was constructed after the fact to try to correct some alignment issues.

I clecoed in the 2024 piece since the alloy seemed more correct. It looks good, but I'll try the 6061 piece next to see what the differences are. If the 6061 looks better, I may use it as a pattern and attempt to make a third one from 2024.

  Dec 17, 2021     Ordered the firewall forward kit. - (3 hours) Category: Logistics

I ordered the firewall forward kit after determining what pieces I already had. I already had the oil cooler, engine baffles, and alternator.
This was added to my existing finishing kit order without requiring an additional deposit.

  Dec 14, 2021     Visited Van's, ordered finishing kit - (1 hour)       Category: Logistics

Visited the Van's counter, Jake helped me order the finishing kit.

We talked about scheduling a factory tour and demo flight. I may wait until the weather gets a bit nicer before I do that.

I learned a little bit about my engine. I was a bit confused about my data tag just saying O-320. It turns out that Lycoming designated that as the O-320-A1A after it was manufactured.

I also learned that once you register your project with Van's, you have access to .pdf versions of the drawings and build manuals on their website. All you need to do is register for a website account and add an aircraft.

  Dec 12, 2021     Moved Fuselage, Wings, and Engine - (6 hours)       Category: Logistics

Enlisted the help of my dad and moved the fuselage, wings, horizontal stabilizer, and engine to my house. The whole plane is here now!

  Dec 11, 2021     Brought home the empennage - (2 hours)       Category: Logistics

Brought home the empennage. Hung the pieces from the garage ceiling for storage.
Also paid for the kit.

  Dec 08, 2021     Organized small parts - (2 hours)       Category: Workshop

Organized the small parts into boxes.
This is just the first step in the organization process.
Began reading the construction manual. This is going to be quite the project!

Found one of the original packing slips. Looks like the kit was originally purchased in 1993.

  Dec 07, 2021     Brought home the first set of parts - (2 hours) Category: Logistics

Brought home a car load of pieces and parts.
Fairings, electrical components, engine components, small aluminum pieces.

  Dec 05, 2021     Clean and prepare the workshop - (6 hours)       Category: Workshop

Cleaned up the workshop, found enough floor to store the aircraft.

  Dec 04, 2021     Project Start - (2 hours)       Category: Research

Met with the current owner of the kit, looked things over, and agreed to purchase.

Additionally, when looking at another aircraft, I met someone who had finished a beautiful RV6A and has been flying it for years. That aircraft is photographed here too.