May 11, 2024     Week 44 - (20 hours)       Category: Wings

Work this week began with installing the proper ground wire on the stall warning assembly in step 5 on page 16iS/U-02. The stall warning assembly was then installed on the nose rib as described in steps 6 and 7. The 1202-L mid wing skin was then located, which required finally un-crating the skins. (The 1202-L skin in buried under about six other skins.) The skin was then fitted over the ribs and the process of adjusting the stall warning tab so that it properly activates the switch was begun. It took a while and repeated attempts to finally get it right. (Step 8 on page 16iS/U-02 and step 1 on 16iS/U-03.) The AOA port was then located and fabricated in steps 2 and 3. In step 4 standoffs for the wing root connector were installed. The process of installing the left wing wiring harness was then begun on page 16iS/U04. Steps 1 through 5 on the left wing were completed. Meanwhile, the inside surface of two of the left wing skins were prepped and primed.

  May 04, 2024     Week 43 - (40 hours)       Category: Wings

With the Cessna moved out of the workshop and virtually all of the prep work done, this week saw an explosion of visible progress on the wings. In summary, starting with 15-04 and finishing with page 15-07, both wings saw the installation of all ribs on the main spars plus the rear spar and stub spar assemblies. We did struggle with some confusion regarding nutplates. Page 15-02 step 9 seems unclear as to whether it is calling for one or two nutplates to be installed. Step 10 clearly calls for two nutplates on another nose rib. At the same time, the detail drawing on page 15-05 shows a single nutplate while the directions in step 5 refer to “nutplates” plural. Then on page 15-07 figure 1 refers to “3 attached nutplates”. We installed two nutplates on each. For now the plan is look ahead to see what the nutplates are for and make adjustments if needed before we install skins. Meanwhile two other projects saw progress. Prep work continued applying Cortec primer on parts for the flaperons. One of our members also spent considerable time working on the stall warning assembly outlined in steps 1through 4 on page 16iS/U-02. He was not happy with the stacking of multiple washers as a substitute for a proper means of providing spacers. But the finished assembly seems to work fine mechanically.

  Apr 27, 2024     Week 42 - (25 hours)       Category: Wings

Early in the week the left and right rear spar assemblies were completed as outlined on page 14-03. Rear spar doubler plates and hinge assemblies were riveted to the rear spars along with tip attach angles. Later in the week we were finally able to make room to bring in the main spars and start assembling the wings. The Cessna project was sent off to have avionics installed and the chapter hangar was rearranged to free up the large table on wheels for wing assembly. This table was earlier used for building components of the chapter's Zenith 750 Cruiser Veteran's Build project. That aircraft is pretty well along and no longer needs the table. Once everything was arranged, we brought in the spars and began work on section 13. Some of this section had been done earlier including steps 1 and 2 on page 13-02 separating and prepping attach angles and doublers. In steps 3 and 4, the left rib doubler had already been riveted to a rib, but otherwise those steps were completed match drilling the doubler to the first inboard attach angle. More attach angles were riveted to the spar as described on page 13-03 steps 1 through 4. Existing attach angles already mounted on the spar also had rivets added to the web of the spar in step 5. Meanwhile, it was discovered that small ribs for the flaperons had not yet been prepped and primed so work was also begun on that.

  Apr 13, 2024     Week 41 - (20 hours)       Category: Wings

This week the focus was on steps 1 through 4 on page 14-2 dealing with the stub spar assemblies. Step 2 requires a 120 degree countersink which we didn't have at first. We ordered a set of bits and got them in time for Saturday's session. Both assemblies were then properly countersunk as described in step 2. Holes at the inboard end of the stub spars were 100 degree countersunk in step 3 and then the two stub spar assemblies were riveted together in step 4.

  Mar 30, 2024     Week 40 - (15 hours)       Category: Wings

Work continued this week with step 7 on page 14-2 creating the flaperon hinge brackets. Steps 8, 9, and 10 were then done completing the assemblies. The stub spars were then brought out and a close examination of the directions and parts for pages 14-02 and 14-03 was done. Nothing was permanently done or riveted at this point pending further review of the directions.

  Mar 09, 2024     Week.39 - (30 hours)       Category: Wings

There haven't been any entries lately for several reasons. For one thing a lot of attention has been diverted to the condition inspection and refurbishment of a Rans S-12XL which was donated to the chapter. That work is now nearly finished and the Rans will soon be sold. Our next kit to complete is the wings, but with the Rans in the way we don't have the room to lay out wings for assembly. Then there's Van's bankruptcy and all the issues that go with that. But when time and space allows, chapter members have been doing what we could in terms of continued prep work on the wings. Almost all wing components have now been primed with Cortec. The nose ribs were prepped and modified according to the directions on page 15-02 steps 1 through 7. Hinge ribs were cut apart in step 8. Nutplates were installed on two ribs and doubler plates were added in step 9. More nutplates were added to another rib in step 10, completing the page. The main ribs are the focus of page 15-03. The ribs were first straightened and trimmed according to the directions on steps 1 through 3. Rib doublers were added to two ribs in steps 4 and 5. When we got to step 6, we realized we had to go back to 14-2 to assemble hinge brackets as outlined steps 5 and 6 on that page. More such prep work will continue until we get the space to actually start assembling ribs onto spars.

  Jan 06, 2024     Week 38 - (15 hours)       Category: Wings

Prep work continued this week. All of the ribs have been done and so now work has moved to some of the longer spar-related parts. Meanwhile, some Pro-seal became available, so a couple of tasks that were earlier postponed were completed. A bead of Pro-seal was applied to the lower outboard edges of the canopy rib assemblies (Step 8 on 29is/U-08.) All of the rivet heads on the firewall parts were also sealed with Pro-seal as directed in step 5 of 29iS/U-09.

  Dec 23, 2023     Week 37 - (10 hours)       Category: Wings

More prep work. Scuff with scotch-brite, clean with acetone, paint with Cortec. A lot of work for an optional step. But in the long run we hope it will be worth it. Who knows where the airplane may end up some day? This way it will be protected and last longer even if it sits outside in a humid environment.

  Dec 16, 2023     Week 36 - (12 hours)       Category: Wings

Prep work continued this week. We don't have room to begin assembly yet due to other projects in the workshop. But the amount of prep work is such that just doing that will keep us busy for awhile.

  Dec 09, 2023     Week 35 - (8 hours)       Category: Wings

Yet more prep work for the wings this week. More ribs were scuffed and cleaned. Parts were also separated and de-burred as described in steps 1 and 2 of page 13-02.

  Dec 02, 2023     Week 34 - (15 hours)       Category: Wings

Prep work continued for the wing kit this week. Fewer members were available for this since attention has shifted to the Cessna 150 project. Still, progress was made. Since we made the decision early on to prime all interior parts, there is a great deal of scuffing, cleaning, and priming to be done before we can even begin to assemble the wings. This is going to take awhile…

  Nov 25, 2023     Week 33 - (25 hours)       Category: Fuselage

Work on the battery box continued where we left off last week. Steps 3, 4, 6, and 7 completed final assembly of the box. Step 5 was skipped for now due to a lack of sealant which is on order. The assembly took awhile because some of the rivets were a little difficult to get to. Meanwhile, looking somewhat ahead, the panel attach strips were prepped by dimpling and riveting nutplates to the panel attach strips (step 6 on 29iS/U-11.) The glareshield was prepped for installation by completing steps 1, 2, and 3 on page 29iS/U-10. Boelube was then applied to the glareshield as directed in step 1 of 29iS/U-11. The mating surface was then cleaned and a bead of Permatex silicone adhesive was carefully laid along F-01201H-1 as described in step 3. The glareshield was then installed on the airframe using screws (step 4.) The small plate that sits on top of the glareshield was then screwed into place. The plate had to be trimmed slightly to fit exactly. The panel attach strips were added next as described in step 7. Meanwhile, a small group assembled the egress handle as outlined in steps 4 through 6 on page 29iS/U-10. The handle assembly was then riveted in place in step 8 of 29iS/U-11. The upper panel plate was then attached to the strips using screws (step 9.) Except for some needed fuel sealant in places, that completed the fuselage kit. For the moment, the fuselage is being set aside in a corner of the chapter hangar. We have the wing kit and a lot of priming prep work needs to be done on that before assembly. Meanwhile, our Cessna 150M restoration project needs some attention since the fuselage has returned from the paint shop.

  Nov 18, 2023     Week 32 - (35 hours)       Category: Fuselage

The forward upper fuselage was the focus of this week's sessions. Beginning with step 1 on page 29iS/U-04, we once again dealt with the messy, thoroughly nasty fuel tank sealant to continue the process of sealing off the firewall. Thus sealed, we then installed and riveted the upper firewall assembly to the fuselage (step 2). In steps 3 and 4, the short cowling attach hinge pieces were match drilled and installed. More sealant was then applied under the F-01201B-1 firewall shelf where it meets the skin. Two stiffeners were then added to each side of the forward skin followed by yet more sealant. We then moved on to page 29iS/U-08 (05, 06, and 07 having been completed.) The F-01202B-1 avionics shelf was first test fitted to be sure the edges aligned with the fuselage side skins. Some minor filing was needed to get a perfect match. Once we were satisfied with the fit, holes were match drilled through the shelf into the 1255 longerons. The canopy rib assemblies were then added and also match drilled. In steps 4, 5, and 6 the shelf, canopy ribs, and 12132 brackets were all riveted onto the 1255 longeron structure. The forward edge of the shelf was then riveted to the upper firewall and nut plates installed. The next step on that page is to add more fuel tank sealant. But by this time the 2 hour pot life of our supply of sealant had expired. So that had to be marked as “to do” and we moved on to the battery box on page 29iS/U-09. The parts for the battery box had been prepped and clecoed together earlier. It was first disassembled and the first two steps were completed. That is where we ended this week's sessions. Steps 8 through 11 on that page were completed earlier.

  Nov 13, 2023     Week 31 - (30 hours)       Category: Fuel System

The main focus this week was on the fuel lines. Last week we spent a lot of time learning how to deal with properly fabricating and bending the fuel lines and managed to complete the first two lines as outlined on pages 27iS/04 and 05. This week we began with the bypass fitting to firewall fuel line on page 27iS-06 which was completed without any problems. Once that was completed we were able to permanently reinstall the rudder pedal and brake assembly. We then moved on to the bypass fitting to tank fuel line on page 27iS-07. This took some time to get right, but was completed without significant issues. It is necessary and acceptable to make small bending adjustments to the tubing to get everything lined up so things fit together. We then moved on to the main filter to bypass fitting line described on 27iS-08 and 09. This was the biggest challenge. It is a three dimensional puzzle that requires careful reading of the plans and a lot of head-scratching. It especially helps to look at the illustrations that show the finished line and how it fits in with the rest of the structure. One of our members, Robert, proved to be especially good at dealing with this puzzle and managed to correctly make all of the required measurements and bends on the first try. It took awhile, but the finished line fit perfectly. Meanwhile, work continued on several components of the upper forward fuselage. The canopy rib assemblies outlined on page 29iS/U-06 were finally completed. A few details were also finished up on the panel base on page 29iS/U-07. Parts for the battery box were also located and temporarily assembled with clecos as shown on page 29iS/U-09. We expect the assembly of the forward fuselage components in the coming sessions. Out Saturday session was cut short so the chapter could host a Boy Scout Young Eagle rally.

  Nov 04, 2023     Week 30 - (30 hours)       Category: Fuselage

Progress was made on several fronts this week. On the upper forward fuselage work continued on page 29iS/U06. The canopy rib assemblies have proven to be more time consuming and confusing than they look. We've already had to replace a part. The right one is finally complete while the left one is awaiting the replacement part. Read the directions very carefully for these parts! Another team worked on the steps on page 29iS/U07. This section is also quite complicated and requires careful reading. By the end of the sessions all steps were completed. Note: We are putting in a single Garmin EFIS, so the directions were followed for that setup. Meanwhile, the rudder pedals were temporarily installed completing steps 8 and 9 on page 28iS/U-03. They are a little tricky to install because of the arrangement of washers, but everything fit well. We later had to remove the pedals temporarily to work on the forward fuel lines. Bending and shaping fuel lines was another challenge begun this week. We began with the fuel tank to shut-off valve line on page 27iS-04. None of us were very experienced dealing with tubing, so we took it slowly and completed the steps on that page. We then moved on to the tube on page 27iS-05. This one was a little more difficult because once fabricated, it does not easily fit where it belongs. The note, “When installing fuel lines it is acceptable to bend a large radius curve by hand to ease installation, the restraighten afterwards” is important. We recruited one of the chapter members working on the Zenith Veterans Build who showed us how to do this. We were able to fabricate the tube and test fit it by the end of the session. Meanwhile, we had some other volunteers show up, so we gave them the task of beginning to prep wing ribs.

  Oct 28, 2023     Week 29 - (35 hours)       Category: Fuselage

Work this week focused on the upper firewall and brake lines. Continuing on page 29iS/U-03, steps 8 through 15 were completed, finishing the page. The upper firewall assembly was then test fitted to the fuselage. Meanwhile, the rudder pedal assembly had been completed up through step 7 on page 28iS/U03. Step 8 involves mounting the completed assembly into the fuselage. Looking ahead, the steps that follow involve adding the brake lines. We decided it would be easier to install the brake lines first on a table rather than try to reach them inside the fuselage. So we moved on to 28iS/U-04 and installed the cross-over brake lines in steps 1 and 2. The tunnel brace in steps 3 and 4 was also installed. The main brake lines were then installed as described on page 28iS/U-05 step 1. Some other parts of the upper fuselage also got some attention. All of the steps separating parts on page 29iS/U05 had been completed earlier. The strut attach angle was fabricated and match-drilled according to steps 1 and 2 on page 29iS/U06. When moving on to step 3, a misreading of the instructions resulted in machine countersinking the wrong side of F-1202M-L. A new part has been ordered.

  Oct 21, 2023     Weeks 27 & 28 - (50 hours)       Category: Fuselage

It has been a busy two weeks with work accomplished on several fronts. The assembly and installation of fluid fittings begun last time and described on page 27iS-02 was completed. The fuel tank was successfully pressure tested using the procedure outlined on page 26iSU-08. The fuel tank and two floor plates, 01229-1 and 01229A, were installed, match drilled, and nutplates added completing steps 5 through 9 on that page. When mounting the fuel tank we found that it is a very tight fit. There is no room for the washer that is supposed to go between the top sides of the fuel tank and the fuselage side as shown in the detail drawing. Meanwhile, the many parts for the forward upper fuselage were prepped with Cortec. The first seven steps on page 29iS/U-03 were completed attaching parts along the upper edge of the upper firewall. Work also continued on the rudder and brake pedals. A match drilling error resulted in one brake pedal not lining up with the others. We ended up ordering a new part and re-doing it which was complicated by the fact that the outer hole was already drilled to full size leaving no pilot hole for match drilling. A lot of time was spent lining things up and finding ways to hold everything in place for drilling. The final solution involved a small drilled hole, a cleco, and a drill press.

  Oct 07, 2023     Week 26 - (35 hours)       Category: Fuselage

Picking up from where we left off last week, work continued on page 24iS/U06. The fuel pump bracket assembly, which had been started earlier, was completed and then match drilled to the left baggage bulkhead. It was then removed, de-burred, and nutplates added completing steps 5 though 12. Filling two holes in the right bulkhead finished step 13 and the page. The steps on page 24iS/U-07 involve the assembly and installation of the rear baggage bulkheads and all of the parts attached to them. Dimpling for nutplates and fluting the lower edges of the bulkheads completed the first three steps. Most of bulkhead assembly is then brought together in step 4. This is a complicated step and should be looked at very carefully. There are many specific overlaps and places where multiples layers are riveted together. We made the mistake of not including the bulkhead layer when first installing nutplates in 01207D-L&R. Luckily this was caught early and quickly corrected. In steps 5 through 8 the overhead bridge piece between the roll bar and the rear bulkhead was assembled and installed. Finally, the Fuel Pump Bracket Assembly was reattached in step nine, completing the page. The F-12109 assembly on page 24iS/U-08 was completed earlier. That left only its installation in step 4. The seat backs, which were mostly completed last week, were finished by installing the seat back brace assembly and the adjustment pins and springs detailed on 25iS/U-05 and 06. We were able to skip most of section 26 since we opted to purchase a finished fuel tank. We began with steps 1 and 2 on page 26iS/U-07, assembling one of the supply/return fittings. Before moving any further and pressure testing the tank we did a brief test fit of the tank in the fuselage. We put off doing anything more in order to let the sealant cure. Looking at section 27, we began the process of assembling fluid fittings and the fuel valve bracket assembly as outlined in steps 1 through 6 on page 27iS-02. Meanwhile, we had a couple of our newer members begin work on the Rudder Pedal and Brake System. First the rudder pedal blocks were cut and formed as outlined in step 1 of page 28iS/U-02. The pedals and blocks were then temporarily clamped together as described in step 2. Brake pedal torque tubes were then added to lock both rudder pedals in the neutral position completing steps 3 and 4. A pair of brake master cylinders were then temporarily attached in step 5. Brake pedals were then added and clamped to the rudder pedals with the whole assembly vertical and perpendicular to the work table in step 6, finishing the page. Holes were then match drilled through pilot holes connecting the brake pedals with the brake pedal torque tubes as described in step 1 of 28iS/U-03. Then a #12 drill was used to final drill all the way through the matched assembly in step 2.

  Sep 30, 2023     Week 25 - (20 hours)       Category: Fuselage

Two projects got some attention this week. The missing bulkheads arrived. They were prepped and work began on parts that are mounted to them. Meanwhile, parts for the seat backs were located and prepped. Then work began on them as well. For the seat backs, preparing parts in steps 1-3 on page 25iS/U-02 was done last week. Hinges for the seat back brace assembly were fabricated and installed on the brace plates as outlined in steps 1 through 4 and 7 through 11 on page 25iS/U-03. (Steps 5 and 6 had been done earlier.) The matching hinge halves were then match drilled and attached to the seat backs in steps 1 through 4 on page 25iS/U04. The heavy frames were added to the seat backs as detailed in steps 5 through 7. Then the adjusting hardware was installed in step 8. The seat back brace assemblies were then attached to the seat backs by fabricating and installing matching hinge pins as directed on page 25iS/U-05. Meanwhile, the first four steps of 24iS/U-06 were completed, match drilling and attaching the F-12110 plate to the left aft bulkhead. Assembly of the fuel pump bracket was next. Steps 5 through 7 were completed which nearly finished the bracket. Our work this week was somewhat limited by the airport aviation day open house. We hosted a pancake breakfast and had aircraft and projects, including the RV-12, on display. We talked to a lot of people, but didn't get a lot of work done.

  Sep 23, 2023     Week 24 - (35 hours)       Category: Fuselage

Thanks in part to tropical storm Ophelia, we had a slightly smaller group working on the RV this week. Still, we got a lot done. Work began with going back to steps 11, 12, and 13 of 24iS/U-02. These steps had been skipped last time due to lack of a #43 drill bit. The switch mounting hole was match-drilled, the backing holes in the roll bar were final drilled to #30 and then the switch plate was tapped to #4-40. This completed page 24iS/U-02. The installation of the canopy latch block was next on page 24iS/U-03. A template was first used to match-drill holes in the bottom edge of the roll bar. Three of the holes were then countersunk and tapped #8-32 for screws. The canopy latch block was then countersunk for the screws and installed. This completed steps 1 through 6. Meanwhile, steps 7 though 13 were also completed, preparing parts and assembling the roll bar supports, finishing that page. The roll bar was then clecoed in place once again in the first step of 24iS/U-04 along with the two support assemblies. The twelve holes on each lower side of the roll bar were then match drilled into the heavy 1231D brackets. The entire assembly, including the brackets, was then removed and de-burred. Everything was then reinstalled and permanently riveted in place. Finally, the bolts for the heavy brackets were torqued and torque seal applied. The last step, unrelated to the others, was to final drill #19 two holes in the aft flange of the left baggage floor. We ran into a problem on the next page, 24iS/U-05. We couldn't find the two 01207C bulkheads. After much searching, we concluded that we never got them, even though we had checked them off on our inventory sheet. We discovered that we had instead two extra 01207D parts which must have been mistaken for the missing 01207Cs. With so many parts having similar numbers it is not a hard mistake to make. We ordered the two bulkheads and will have them next week. In the meantime, we prepped and primed all the parts that are called out on page 24iS/U06 that will be attached to the bulkheads. Similarly, nutplate rivet holes were dimpled and some holes machine countersunk in parts as called out on page 24iS/U07. The first three steps of page 24iS/U-08 were also done completing the F-12109 assembly. Also completed was the installation of the cowling hinges detailed on page 23iS/U-09.

  Sep 16, 2023     Week 23 - (35 hours)       Category: Fuselage

The main focus of this week's sessions was the rollover structure beginning with 24iS/U-02. It took a little while to figure out the puzzle of how all the roll bar components go together. There was a lot of checking, examining the plans, and rechecking before anything got put together. Of particular note are the F-1231E plates. Only one is shown on the illustration and it would be easy to leave the forward one out of the structure. Once we were satisfied that all was understood, the roll bar assembly was clecoed together. The heavy 12321D brackets were prepped in step 2 and then loosely bolted to the airframe in step 3. The roll bar assembly was then clecoed to the brackets in step 4. Steps 5 and 6 involved final drilling and match drilling holes in the roll bar and C-01213A latch piece. Everything was then disassembled and de-burred. The holes in the outer flanges of the roll bar assembly were then machine countersunk along with the holes in C-01213A and specific holes in the face of the roll bar. Steps 11, 12, and 13, which involve part 01231F-2 were temporarily skipped because we lacked a #43 drill bit. The bit will be ordered and those steps completed next time. The roll bar assembly was then clecoed back together and then riveted together as directed in steps 15 and 16. Meanwhile, work continued on installing the lower cowl hinges, following the steps on page 23iS/U-09. The directions were followed exactly, but the fit of the hinges is not precisely as illustrated. There is about 1/16 space between the edge of the skin and the row of hinge tabs. That may require more investigation.

  Sep 09, 2023     Week 22 - (40 hours)       Category: Fuselage

The side skins and related structures were the main focus this week on the fuselage. The skins continued to be prepped while work resumed on 23iS/U-05. Arm rest tabs were match drilled and de-burred. Then the arm rests were riveted in place at directed in steps 3 and 4. The longerons were then fitted along with the canopy decks and clecoed in place, which completed the steps on 23iS/U-05. By this time prep work on the skins outlined on page 23iS/U-06 had been completed. The process of installing the skins was then begun with the steps on page 23iS/U07. Meanwhile, as a separate project, work was also begun on the small vent door assemblies detailed on page 23iS/U-08. Small triangular reinforcements were first riveted to the forward vertical structure in step one of 23iS/U-07. Then the skins were fitted. The longerons, canopy deck, and skins were clamped together and match drilled. Specific holes were then machine counter sunk and the entire assembly removed and de-burred. The bottom and aft edges of the skins were “broken” (edges curved inward slightly), nutplates were added, and the rear tabs were removed. The skins were then reinstalled and tape was used to cover holes that were not to be riveted at this stage. After carefully reviewing the rivet and countersink call-outs on page 23iS/U-10, riveting was begun starting with the cherry max rivets. Near the end of skin riveting the vent doors were added and the rear side stiffeners installed. This completed 23iS/U-07 and U-08. While the riveting was taking place, some time was spent preparing for the steps on page 23iS/U-09. The lower cowl hinges were located and cut to size, completing step one on that page.

  Sep 02, 2023     Week 21 - (30 hours)       Category: Fuselage

The week began with finishing the process of altering the two longerons by opening one end by 5.4�nd then twisting that end by 2.7�Once that was finally accomplished, the longerons were completed by match drilling and clecoing the F-01234 canopy deck plates to them. This completed all steps on page 23iS/U-02. Meanwhile, the roll bar attach plate was prepped by completing steps 1 and 2 on page 23iS/U03. The installation of the mid fuselage brace was then begun adding parts 01205A, 01205B, 01205C as outlined in steps 3 and 4. The narrow seat back adjustment plates were then added to the brace as described in step 5. We were a little confused at first which way they faced, but fortunately an experienced RV-14 builder stopped by who set us straight. This completed all steps on page 23iS/U03. The two F-01204J plates were carefully identified by side and then machine countersunk. They were then riveted to the existing structure completing steps 1 and 2 of 23iS/U-04. Steps 3, 4, 8, and 9 simply involved separating parts, riveting the arm rest brackets, and removing a tab from the arm rests. Meanwhile, holes were dimpled in the canopy decks and the corresponding holes machine counter sunk in the longerons as described in steps 6 and 7 which completed 23iS/U-04. Four vertical braces, 1202E and 1203G, were then riveted to the structure completing the first step on page 23iS/U-05. Meanwhile, looking ahead to 23is/U-06, the process of prepping the side skins was begun. The inside surface of the left skin was primed with Cortec. Then the tedious task of enlarging the opening for the wing spars was begun. That concluded our sessions for the week.

  Aug 27, 2023     Week 20 - (30 hours)       Category: Fuselage

It was a busy week with a lot of interruptions, but still good progress was made on the RV-12. The week began with the first steps of page 22iS/U-05. Parts were scuffed in preparation for the application of tank sealant. Then the lower firewall, bottom plate, and console sides were riveted together as outlined in steps 2 and 3. The seven nutplates were also added along the bottom edge of the center firewall/bottom plate. It was then time to add tank sealant. This is messy stuff. First it has to be mixed and then carefully applied where directed. Once mixed it cannot be stored for any significant amount of time, so any remaining sealant must be thrown away. Seems a waste considering the small amount that is used for these steps. The shelf was then riveted to the top flange of the firewall with the sealant between them. Sealant that was squeezed out in the process was cleaned off with acetone. The sealant remains very sticky for a long time and parts have to be handled carefully. Thoroughly nasty stuff. The two diagonal stiffeners along with the 00088A&B bracket were installed onto the firewall as described in steps 6 through 9. The first step of page 22iS/U-06 added curved skins to the sides of the forward assembly. Then the small cowling attach plates were installed on the curved surface of the forward edge of the firewall as outlined in steps 2 through 5. The next step, on page 22iS/U-07, was to turn the fuselage over and attach the completed forward assembly. This completed the 22iS section. 23iS/U-02 involves the strange exercise of making changes to the two longerons. The aft ends of the longerons were first trimmed. Then came the challenge of opening the 90�ross section of the longeron by 5.4�This involved the use of a vise and a 1/2 inch socket to progressively force the heavy angle open. We only got one longeron opened to the correct angle as described in step 3. The rest of this process will wait until next time. (On Thursday we were interrupted by the arrival of a Rans S-12xl that had been donated to the chapter. Two of our members had journeyed all the way to Houston Texas to get it. We helped unload the aircraft and then on Saturday spent time during our session reassembling it. Once inspected, the plane will be sold as a fundraiser for the chapter.)

  Aug 19, 2023     Week 19 - (30 hours)       Category: Fuselage

This week began with the attachment of a fuel tank pad to the aft center section bulkhead which completed the final step of section 21iS. All of the steps on page 22is/U-02 involved separating and preparing parts and were quickly completed. Page 22is/U03 began easily enough with dimpling and the installation of yet more nutplates onto the F-01201C-1 lower firewall bulkhead. Steps 4 through 8 also went smoothly, assembling F-01257-1 brackets and nutplates to the F-01201B-1 shelf. It was step 3 that gave us trouble. The isometric view confused everyone who looked at it. The result was that we machine countersunk the wrong side of the F-01272-1 plate. We called in our resident A&P expert who fabricated a set of small doublers that would provide the necessary material thickness to properly countersink and rivet from the other side according to the directions. With that problem solved, we moved on to page 22iS/U-04. The focus of this page is the assembly of the console. Holes were countersunk and dimpled according to the directions in the first three steps. A step drill was used to enlarge the holes called out in step 4. Then the WE-1204 brackets and F-12131 stiffeners were final drilled and riveted to the F-01217 console sides and nutplates installed. Step 8 completed the page with the riveting of the console sides to the F-01272-1 floor plate. Page 22iS/U05 requires the use of fuel tank sealant along the firewall seams. We ordered sealant, but it has not yet arrived. So looking ahead the assembly on that page was test fitted, but not riveted. Parts for the following page were also located and primed. We also took a look ahead to 23iS/U-02 which involves what appears to be a challenging task of fabricating the longerons.

  Aug 12, 2023     Week 18 - (45 hours)       Category: Fuselage

This week started with the first steps of 21iS/U-19. This involved separating and preparing the six sets of fuselage corner skins. Everything so far has been internal parts and we have been routinely priming everything with Cortec. Unfortunately, we applied Cortec to both sides of the corner skins, so the primer will have to be removed from the outer sides. Need to begin watching more carefully what is interior vs. exterior. Nutplates were added to the two F-01275F skins, then the skins were riveted to the existing structure which finished all the steps on that page. Parts were separated and de-burred according the steps on page 21iS/U20 with the exception of the F-12113 plate which is not installed on the iS version. Attention then turned to the bottom skin on page 21iS/U21. The access holes were dimpled and nutplates riveted in place. The F-00020 plate was also riveted to the skin. Six system block studs were lubricated and then installed through the skin finishing all steps on that page. The edges of the bottom skin were “broken” (slightly curved inward) and then the skin was clecoed to the structure. The six F-1204Z braces were then clecoed in place by reaching through the structure to align each one. Next, the six triangular F-1268 doublers were clecoed in place and then both braces and doublers were riveted to the skin. Tape was added to cover holes that were not to be riveted and then, with the help of some of our younger members, the skin was riveted to the fuselage structure. Tasks on page 21iS/U23 began with dimpling the two F-01213 floor plates, again assisted by our younger crew. Nutplates were added then the fuselage assembly was turned right side up and the floor plates riveted to the structure. The final step in attaching the floors proved tricky. Nutplates had to be installed in the top flange of the F-01202 bulkhead which had been rendered nearly inaccessible by installation of the floors. By reaching through lightening holes and slightly lifting floor corners, the nutplates were finally installed. Parts were separated and de-burred completing all steps on that page. Moving to the rear of the fuselage, 21iS/U-24 involved attaching a plate to the rear ribs and adding brackets and snap bushings. Holes were first dimpled for nutplates and the nutplates installed. The F-12108A bracket was then riveted to the F-01207B-1 plate. The plate was then clecoed onto the rear ribs and then brackets, F-01286A-L&R, were riveted through the plate into the ribs. The bracket assembly was completed by riveting the two F01286B-L&R parts to the existing F-01286A bracket. Snap bushings were then installed. The final step of that page and of the entire section involves attaching a fuel tank pad. We haven't done that step yet. Next time.

  Aug 05, 2023     Week 17 - (35 hours)       Category: Fuselage

Work continued on the cabin structure this week with page 21is/U11. The right seat floor was riveted in place similar to the left seat floor done earlier. The two floor assemblies were then riveted to the center section bulkhead. Step 4 was also completed, bolting a 1204R plastic block to the frame. Another plastic block was then bolted to the structure in step 1 of page 21is/U12. The next steps involved riveting plates to the vertical members of the center section bulkhead, 1204H and 1204B. Rollers were then added to the lower ends of those members (1204M). Parts were separated and prepped in steps 1 and 2 of page 21is/U-13. The remaining steps on that page involved preparing another bulkhead for adding to the structure. Holes in the bulkhead were countersunk and some were enlarged. At either end parts 1203C, 1203B, and 1203D were riveted to the bulkhead. More parts were added to the 01203A-1 bulkhead on page 21is/U-14. 1203E parts were separated, riveted to each other, then riveted to the bulkhead. Further work on the bulkhead continued on page 21is/U-15. 1203J parts were separated and riveted onto the bulkhead. Nutplates were also added. The completed 01203A-1 bulkhead was then installed onto the cabin structure in the first two steps of 21is/U-16. 01226 plates were then added to either end of the structure in steps 3 and 4, followed by the installation of nutplates in step 5. Tasks on page 21is/U-17 began with a time-consuming and somewhat difficult job of separating then precisely tapering a set of heavy L brackets. The finished brackets were then riveted to four “step ribs” to form two step rib assemblies. The first steps of page 21is/U18 involved the complicated process of attaching the step rib assemblies to the 01203A-1 bulkhead and adding the smaller 01202F bulkhead to the the front of the rib assemblies. (There are many, very specific instructions in that process.) The final steps on page 21is/U18 were to add a number of snap bushings plus a fairlead to the overall structure. This required turning the structure over to more easily get at the bushing locations.

  Jul 30, 2023     Week 16 - (36 hours)       Category: Fuselage

Good progress continued this week on the RV-12 fuselage. The first tasks were those on page 21is/U-05. Completing for now the baggage compartment bulkhead assembly, steps one through five were done, including the installation of the bearing bracket assemblies. The entire bulkhead assembly was then set aside. The pulley bracket was assembled in steps six and seven. Then the complicated flaperon mixer arm was assembled completing steps eight through twelve. Page 21is/U06 began with separating and deburring a number of small parts. The eight seat ribs were then numbered and the small parts attached to some of them, completing part of the right seat rib assembly. More work on the seat ribs continued on 21is/U-07. Holes were drilled and dimpled, nutplates added, and the F-1269 plate installed. Page 21is/U08 was also completed by installing the pulley bracket assembly to ribs #5 and #6 along with the flaperon mixer arm assembly to ribs #3 and #4. Continuing to page 21is/U09, nutplates were added to two sets of F-01267 A-1 and F-01267B-1. Then those parts were installed between ribs #2 and #3 and between ribs #6 and #7. The final page of the week was 21is/U10. This involved preparing the seat floors for attaching to the rib assemblies by dimpling and adding nutplates and then installing the floor for the left seat. So six pages of good progress in one week.

  Jul 23, 2023     Week 15 - (28 hours)       Category: Fuselage

In spite of some more interruptions, steady progress was made on the RV-12 this week. Picking up where we left off, the first task was assembly of the ELT bracket followed by riveting of the bracket to two of the baggage ribs. This completed all of the steps on page 21isU-02. Continuing on to 21isU-03, the baggage ribs were riveted to the assembly and nut plates installed according to the plans. The baggage bulkhead was then assembled which included riveting the stub spar plates to either end, dimpling holes along the top edge, and installing nut plates. Completing 21isU-03, nut plates were riveted to two square baggage ribs. Moving on to 21isU-04, bearing bracket assemblies were riveted together. The baggage bulkhead was then added to the assembly along with the four square short ribs. Nut plates were also added to the baggage floors. The final step on 21isU-04 was to trim and separate an L bracket. That was where we ended for the week.

  Jul 17, 2023     Week 14 - (45 hours)       Category: Fuselage

A lot was accomplished on the RV-12 this week. This was partly due to an extra session that took place while waiting all day for the wing kit to arrive. Work continued to be focused on the main center section spar carry-through. Step 8 on 20isU-03 was completed after some discussion and research on the meaning of the directions which seemed to contain a double negative. The skin stiffeners were then added, completing all steps on 20isU-04. Next came the skin attach flanges and aft side bulkheads on page 20isU-05. All of those steps were completed. It was then on to the next section. Fuel tank pads were cut and riveted. Holes were dimpled and nutplates installed in the baggage floors. The floors were then riveted to the main center section assembly. This completed steps 1 through 6 on 21isU-02. In the middle of all of this the wing kit arrived. It came late in the day so we didn't have time to do much with it. The next session may be devoted to inventorying that kit.

  Jul 08, 2023     Week 13 - (20 hours)       Category: Fuselage

This week we finished the hardware inventory and began the first steps in the fuselage build. All of the parts set aside earlier were scuffed, cleaned, and primed with Cortec. Assembly was then begun with the installation of plate nuts. Parts were then match drilled, dimpled, and machine counter sunk according to the instructions. We completed all of the steps on 20iSU-02 plus steps 1 through 7 on 20iS-03. Meanwhile, we've been notified that the wing kit is on the way. It is scheduled to arrive sometime on July 11th.

  Jun 24, 2023     Week 12 - (20 hours)       Category: Fuselage

Finally! The fuselage kit arrived the middle of June, but had to be put aside due to the Ford Tri-Motor visit. On Saturday we began the process of inventorying everything. We're not quite finished the hardware inventory, but everything else was accounted for with only a couple of minor exceptions. We referred to the plans and located all the parts necessary for the first few steps and set them aside. The rest of the parts were organized into plastic bins. In spite of some upcoming interruptions (condition inspections and vacations) we expect to resume build sessions soon.

  Feb 12, 2023     Waiting... Category: Empennage

The reason we haven't posted anything recently on the RV-12 project is because we are waiting on parts. We have completed the empennage kit and are now waiting on the fuselage and wing kits, which are supposed to arrive sometime in April or May. Meanwhile, we've been working on the chapter's Cessna 150 project and Veteran's Zenith 750 project. So we're still keeping busy.

  Nov 05, 2022     Day 20&21 - (35 hours)       Category: Empennage

Work resumed on the fiberglass tip fairings. (12is/U02-04) The rudder fairing which had been started last time was first completed. The vertical stabilizer fairing was next, which not only had to be fitted to the stabilizer, but also had to be matched to the rudder fairing to ensure there was no interference. Finally, the stabilator fairings completed the set. We found that once we fitted a fairing for one side, it fit fine on both sides. So we were able to use the first one as a template for the other. All of the fairings were first sized and given their approximate shape using a belt sander, then final shaped using files. With that completed, the stabilator, vertical stabilizer, and rudder were moved out of the chapter workshop for storage. The only remaining part that we could assemble was the pitch trim servo pushrod assembly (11is/U08 steps 4 through 8). That completed, the only remaining steps involve installing the servo (11is/U08 steps 1 through 3). For storage reasons, we are waiting to assemble the empennage components together until later. So at this point we are basically waiting on our next kit.

  Oct 29, 2022     Days 18&19 - (40 hours)       Category: Empennage

The focus of these sessions was the completion of the tail cone assembly. It was decided to configure the pitot lines and connections for the Garmin system. All of the steps on page 10is/U09 were then completed. We then moved on to 10is/U10. The snap bushing brackets and bushings were installed and a string routed through the bushings and rudder control cutouts and run to the front of the assembly. Finish riveting of the left and right side skins completed 10is/U10. Installation of the top skin as outlined in 10is/U11 was next. The skin went on easily and everything matched up very nicely. Holes were match drilled to the F-1210C angle and the assembly check for deformations of the skin. We found none, but filed the edges of the angle slightly to be sure. The vertical stabilizer forward skin rib, which had been assembled earlier, was then riveted to the top skin. This was soon followed by the the forward J-Stiffener and ADAHRS brackets. All that was left was to final rivet the entire assembly, completing all steps on 10is/U11. We then moved the completed tail cone to another hangar for storage. Other than the assembly of all the components together, which will come later for storage reasons, the only thing we had left to do was the cutting and fitting of the optional fiberglass tip fairings. We got a start on that with the fitting of the rudder fairing. Meanwhile, looking ahead to the eventual mating of the stabliator/anti-servo tab to the tail cone, the anti-servo tray was assembled according to the instructions on pages 11is/U05 and U06. The next sessions will be Thursday, November 3rd and Saturday November 5th.

  Oct 22, 2022     Days 16&17 - (35 hours)       Category: Empennage

Work continued on the RV-12 beginning with step 7 of 10is/U06. We arranged a set of tables to give us the proper height, joined the two bottom skins together, and attached the bulkhead frames. We then went on to the steps on page 10is/U07, attaching the left and right lower skins to the bulkhead frames. The assembly was then riveted together according to the directions. At that point it was time to install the reinforcing braces along the bottom skins called for in service bulletin SB-00053. With that accomplished we moved on to the steps on page 10is/U08. Early steps involved the installation of the rear F-1211 assembly onto the tail cone and the addition of two side skins. A string was then routed through the stabilator control cutouts and run to the forward end of the tail cone. The wire for the trim was also installed. Meanwhile, some of us skipped ahead a little and assembled the nut plates onto the forward skin rib as described on page 10is/U11 steps 1 through 5. The installation of the pitot system tubing was then begun following the instructions that came with the system kit. Most of the steps on page 10is/U09 for installing the system were also completed, although work paused for a lengthy discussion of Garmin vs. Dynon instruments. Some parts of the pitot system are different depending on which you choose. The next sessions will be Thursday October 27th and Saturday October 29th.

  Oct 13, 2022     Day 15 - (16 hours)       Category: Empennage

The day began with a discussion of rivets. It was earlier discovered that one of the bags from Van's contained the wrong rivets. (The bag contained AN426AD4-6 rather than the labeled AN470AD4-6 rivets.) Riveting the control horns onto the stabilator box spar assembly required four AN470AD4-6 rivets. (Step 9, Page 9is/U04) Another chapter member had built an RV and had left over rivets in a container marked AN470AD4-6, so we used four of those to rivet the horns. Later, the sharp eye of one of our members noticed that there was no dimple in the rivet heads and questioned whether they were actually high strength AD rivets. A little research and experimentation later revealed them to be significantly lower strength rivets. So part of today's session involved drilling out and replacing the rivets. Lesson learned: Make sure all rivets are actually what the inventory says they are and make sure they all have dimples. Once the rivets were replaced, the tricky task of testing the fit of F1211 assembly to the stabilator was accomplished. (10is/U05) The right number of washers was determined and the joined assembly works smoothly. Meanwhile, work began on the tail cone skins which were prepped and primed last time. A tool was used to break some of the edges according to step 2 of 10is/U02. We then went on to complete steps 1 through 6 of 10is/U06 attaching J-stiffeners to the bottom left and right skins. The next session will be Thursday, October 20.

  Oct 08, 2022     Day 13&14 - (40 hours)       Category: Empennage

On Thursday the focus was mainly on completion of the stabilator. All steps on page 9is/U08 were completed which included the anti-servo hinges and aft skin installation. Meanwhile, many of the parts for the tail cone were prepped and primed. Assembly of the tail cone bulkheads was then completed (Steps 3 through 10 on page 10is/U02.) Work was also begun on the complex rear bulkhead (page 10isU/U03). On Saturday the rest of the rear bulkhead was completed finishing all steps for the F-1211 assembly on page 10is/U04. The process of doing the initial fitment test of the F1211 assembly to the the stabilator was begun (10is/U05) but not finished. The tail cone skins were also brought in, identified, prepped and primed. The next session will be Thursday, October 13th.

  Oct 01, 2022     Days 11&12 - (45 hours)       Category: Empennage

A lot of visible progress took place during these two sessions. We had decided to go back and bring the process up to date by completing the components that had earlier been skipped due to missing back ordered parts. With parts in hand we completed the vertical stabilizer and rudder. That brought us back up to where we left off with the stabilator. In earlier sessions we had completed the stabilator skeleton assembly. So we began with the installation of the skins (page 9iS/U07). The process went pretty smoothly and everything lined up remarkably well, a testament to Van's precision engineering and manufacturing. We completed all of the steps on page 9iS/U07. Next session we will finish the stabilator beginning with the steps on page 9iS/U08. That session will be Thursday, October 6th.

  Sep 24, 2022     Days 9&10 - (20 hours)       Category: Empennage

As we prepared to continue work on the stabilator, we discovered that an important part of that assembly involved hinges that are supposed to be created when building the anti-servo tabs. Along with parts of the vertical stabilizer and rudder, we had skipped the anti-servo tabs because they required parts that were on back order. The parts have since arrived, so we decided to put the partially completed stabilator on hold and go back and complete the earlier parts so that we can stick to Van's order of doing things. So all parts for the anti-servo tabs and the ribs for the vertical stabilizer were prepped, cleaned, and primed. The anti-servo tabs and their hinges were completed. (Our first complete parts!) And assembly of ribs onto the vertical stabilizer spar was begun. The next session will be Thursday morning, September 29th.

  Sep 17, 2022     Days 7&8 - (40 hours)       Category: Empennage

The last two sessions focused on the stabilator. The box-like spar was clecoed together and parts were final drilled. Meanwhile, all of the ribs were prepped, cleaned and primed. The spar was then disassembled and de-burred. Steel brackets that required AN solid rivets were installed which required the use of a pneumatic squeezer. The spar was then carefully reassembled and riveted together. Finally, the ribs were added to the spar to complete the framework. The next step will be to check everything and then begin putting the skins on the frame. The next session will be Thursday, September 22nd.

  Sep 10, 2022     Day 5&6 - (35 hours)       Category: Empennage

On Thursday, the focus was on parts of the vertical stabilizer and the rudder. Both are lacking a lot of back ordered parts, so there was only so much that could be done. The front spar for the vertical stabilizer was trimmed, fluted, and adjusted to fit with the stabilizer skin. Attach brackets for the rudder spar were fitted and bolted onto the spar. The rudder control horn was fitted and clecoed onto the spar as well. Vertical stabilizer and rudder parts were then set aside awaiting parts that should arrive soon. Meanwhile, on Saturday we moved on to the stabilator which is the first major component that has no missing parts. We were joined by Mia, our Ray Aviation scholar and her father for this session and we made good progress. Parts were located, prepped and primed with Cortec. Brackets were riveted together and plate nuts installed. Work also began on assembling the complicated box-like stabilator spar. The next session will be Thursday, September 15th.

  Sep 03, 2022     Days 3&4 - (25 hours)       Category: Empennage

Construction of the RV-12 began on Thursday with the vertical stabilizer. Wedges for riveting were first fabricated and attach brackets for the rudder were prepped and assembled. A lot of time was spent on the long rear spar and its components. By the end of the sessions it and all of its attachments were complete and riveted together. We couldn't go any further with it since the ribs for the vertical stabilizer are on back order. Some time was spent dealing with the new electric rivet gun. It took awhile to get it to work properly. Mandrels kept getting stuck inside instead of ejecting out the back. After disassembling and cleaning out some sticky oil, it now seems to be working fine. Attention then turned to the vertical stabilizer skins which require a lot of dimpling and the installation of plate nuts. With that accomplished, the vertical stabilizer is as complete as we can get it for now awaiting the back ordered ribs. The next session will be Thursday, September 8.

  Aug 30, 2022     Days 1&2 - (25 hours)       Category: Empennage

The RV-12 empennage kit arrived on Wednesday. We uncrated the kit and did an overall inventory of parts. Some parts are back ordered. On Saturday, some parts for early steps were located, cleaned, and primed. Further work on a more detailed inventory was also done. Large parts were moved out for storage and the crate disposed of. It was decided that we would open the project to chapter members and that Saturday and Thursday mornings would be formal work sessions. The next session will be Thursday, September 1st.