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.