Project: pchang   -  
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Builder Name:Paul Chang   -  
Project:   Vans - RV-10   -   VIEW REPORTS
Total Hours:619.75
Total Flight Time:
Start/Last Date:Jun 22, 2022 - No Finish Date
 
Friendly URL: https://eaabuilderslog.org?s=pchang

Home or Last Project Picture

May 09, 2024     EFRT; 11-13 through 12-13; all steps - (1.8 hours)       Category: Wings
created a new access panel per ER fuel tank instructions. Measured and drilled out the access panel hole. Deburred and ready for the new access panel doubler when the skins have been completely prepped and ready for riveting.


 
May 08, 2024     Sect 20; 20-5 Steps 2-5 left wing - (1.3 hours)       Category: Wings
Removed blueing from the back of the skins. Inserted the Wing box j stiffiners and put on the skins. Cleco'd them in place and match drill the #40 holes that needed match drilling. Also drilled the #40 and #19 size holes for nutplates in the inboard skin edge.


 
May 06, 2024     Sect 20: 20-6 Step 1-4 right wing - (1.7 hours)       Category: Wings
Access panel deburred, drilled, and dimpled. Installed nutplates on the wings, also installed the trim servo. Closed everything up on the right wing.


 
May 05, 2024     Sect 20: 20-5 Step 11-12 right wing - (9.7 hours)       Category: Wings
Riveted the outboard bottom wing skin.


 
Apr 29, 2024     Sect 20: 20-5 Step 2-10 right wing - (10.8 hours)       Category: Wings
Deburred, filed, match drilled, primed, and riveted in place the right inboard bottom wing skin.


 
Apr 07, 2024     Sect 20: 20-4 Step 1 right wing ; Trim servo - (3.8 hours)       Category: Wings
Built out the trim servo. Same deal, cut, deburr, paint, and installed onto the access panel.


 
Mar 15, 2024     Sect 20: 20-4 Step 1 left wing - (.6 hour)       Category: Wings
Spliced together the wires for the regulator and fed it through the left wing conduit.


 
Mar 13, 2024     Sect 20: 20-4 Step 1left wing - (2.1 hours)       Category: Wings
Installed the conduit line for the left wing by drilling and riveting the conduit clips, Then installed the conduit and zipped tied it to the conduit clips. Ran the lines for the lighting and GAP 26 regulator. Primed and installed the regulator mount stiffeners and screwed them in place.


 
Mar 09, 2024     Sect 20; 20-5 Steps 3-9 Right wing - (5.5 hours)       Category: Wings
Clecko'd the wing skin onto the wing. Match drilled and deburred W-1005R wing skin.


 
Mar 05, 2024     Sect 20: 20-4 Step 1 left wing - (3.7 hours)       Category: Wings
Installed the autopilot, wires for zip tips and RF antennae on the right wing. Housed them in the conduit that I attached with vans wire clips. Ordered a few items for the installation: Garmin autopilot mounting kit, wire pliers, butt splices, and more non standard rivets. Looking ahead, I had to order 2X VA -162 because I did a horrible job installing it..


 
Feb 28, 2024     Sect 20: 20-4 ; step 5-6 - (2.4 hours)       Category: Wings
Riveted both the aileron and flap gap fairings to the wings.


 
Feb 27, 2024     Sect 20 ; 20-4 Step 4 - (1.75 hours)       Category: Wings
Dimpled and primed all the pieces including the inside of the tubes and brackets for the actuation in section 23


 
Feb 26, 2024     Sect 20; 20-4 step 2-4 - (2.3 hours)       Category: Wings
Cut out the stiffeners, deburred all the edges and holes, washed. Ready to prime.


 
Feb 18, 2024     Sect 20: 20-2 step 4-6 - (.6 hour)       Category: Wings
Going with the garmin GAP 26 regulated pitot tube with AOA. Installed the bushings and sleeve to both the AOA and Pitot line. Will have to come back to this to install the garmin mast and pitot on the wings.


 
Feb 17, 2024     ERFT; 12-14; Fuel tank test - (3.5 hours)       Category: Wings
Checked for leaks on the fuel tank and found a small leak. Borrowed a vacuum pump and put negative pressure in the tank and thinned out the proseal with a little ethanol. Using a syringe, pushed the proseal at the site of the leak and made sure there was ample amount of sealant to continue to draw proseal to seal the leak. It turned out well and then installed the tank to the wing.


 
Jan 10, 2024     ERFT; 12-14; steps 1-6 - (2.7 hours)       Category: Wings
Installed the baffling and the z brackets on the right fuel tank. Sealed with Proseal and riveted everything together. The work was done in a span of two weeks. Next up is to seal test.


 
Dec 17, 2023     Sect 23 - 2 Steps 1-4 through Sect 23-3 steps 1-2 - (4.8 hours)       Category: Wings
While the right fuel tank is curing. I started fabrication of the two torque tubes. Primed and installed the nut and o ring to each tube. Also started work on the bellcrank pushrod by cutting them to length and fitting the AN490HT8P. Just need to prime the insides before final riveting.


 
Dec 10, 2023     ERFT; 16-3; 13-14 steps 1-2 left - (2.7 hours)       Category: Wings
Spent 2 hours fitting the left ER fuel tank.


 
Nov 30, 2023     ERFT; 16-3; 7-14 steps 3-4 through 8-14 steps 6 - (3.1 hours)       Category: Wings
completed the inboard rib and all the attachments. Riveted and sealed off. Will allow a few days for the proseal to set up and then test.


 
Nov 27, 2023     ERFT; 16-3; 7-14 steps 1-2; continued - (4.2 hours)       Category: Wings
completed the riveting of all the tank nose ribs and also attached and riveted the tank j channel. Completed proseal sealing the rivet heads on all riveted rivets.


 
Nov 23, 2023     ERFT; 16-3; 7-14 steps 1-2 - (1.7 hours) Category: Wings
Prepped and installed/riveted the first 2 ribs on the inboard side of the right fuel tank. Very messy and time consuming work that is also time sensitive....
 
Nov 14, 2023     ERFT; 16-3; 6-14 steps 1-2 - (2.2 hours)       Category: Wings
Cleaned the stiffeners with alcohol and riveted them to the skin using Proseal. Also installed the fuel cap flange and the VA-112 fuel drain flange.


 
Nov 12, 2023     ERFT; 16-3; 4-14 through 5-14 steps 1-8 - (14.7 hours)       Category: Wings
completed all the steps on page 5. Took the entire weekend to do. Summary of work was working on the J stiffiner, baffling, and dimpling of the skin. Also attached the parts to the ribs that is associated with the gas plugs. Also ordered more Proseal


 
Nov 09, 2023     ERFT; 16-3; 4-14 Right tank skin deburr and scuffing of holes - (2 hours)       Category: Wings
Tedious work that had to be done, I deburred all the inside holes and scuffed up the inside tank skin.


 
Nov 05, 2023     ERFT; 16-3; 12-14 steps 1-6 Left Tank - (4.2 hours)       Category: Wings
Installed the baffling using rivets and proseal called out in the instructions. After curing for 2 days, I went in and installed the z brackets. Then I countersunk and riveted the 10 #40 holes aligning the skin to the baffling. 1 tank done!


 
Oct 25, 2023     ERFT; 16-3; 2-14 steps 1-6; right tank - (2.7 hours)       Category: Wings
Same process as the left wing tank. Deburred, cramped, final drill, and deburred the holes on all the tank ribs.


 
Oct 23, 2023     ERFT; 16-3; 9-14 steps 1-3 - (3.7 hours)       Category: Wings
Installed the fuel sender, then cleaned up the inside of the tanks a bit.


 
Oct 21, 2023     ERFT; 16-3; 8-14 steps 1-6 - (4.5 hours)       Category: Wings
installed the aluminum vent line and the riveted the inboard ribs to attach those vent lines. Applied sealant.


 
Oct 18, 2023     ERFT; 16-3; 7-14 steps 1-3 - (11.7 hours)       Category: Wings
Took most of the week to install the tank ribs. I only had a 2 hour window to install 3 ribs starting from when I mix the proseal. In a 2 hour window, i was able to install 3 tank ribs. This includes putting the proseal on the rib flanges, place the ribs into the skin, cleco 3 on each side, rivet them in place, and finally putting proseal on the rivets inside. I also completed installing the J Stiffeners using the same method. Lastly, I also installed the T-1005 tank attachech bracket subassembly onto the tank, also using the same method of proseal, riveting, and presealing the rivets on the inside.


 
Oct 10, 2023     ERFT; 16-3; 5-14 steps 7-8 through 6-14 steps 1-2 - (8.8 hours)       Category: Wings
riveted and prosealed the t-1010 anti rotation plate and the VA-141 fuel flange. Riveted the K100-3 nutplates. On the tank skins, applied proseal and riveted on all the tank stiffeners and both the fuel cap flange with the vent line clip. Lastly pro sealed and riveted drain flange.


 
Oct 01, 2023     Finished up the forward edge - (1.7 hours)       Category: Wings
Finished up riveting the forward edge and any remaining ER fuel tank brace on the wing spar. Also screwed down the aftermarket aileron brackets from sky designs engineering.


 
Sep 27, 2023     EFRT 16-3-5 Steps 1-5 - (1.8 hours)       Category: Wings
Completed the shims prep work and riveted them in place, installed the VA-146 flange bearing. Got shipment of nuts and washers from aircraft spruce and was able to complete the sky design aftermarket aileron brackets as well as sizing the hole for the vent line bracket.


 
Sep 25, 2023     Rivets, pneumatic puller, nuts Category: Tools
 
Sep 24, 2023     ERFT; 16-3-4; step 5-14 - (5.5 hours)       Category: Wings
Countersunk the skin where the baffles are attached, dimpled all tank pieces, machine countersunk the fuel cap flange


 
Sep 23, 2023     ERFT; Deburred Left Fuel tank skin - (5.4 hours)       Category: Wings
Deburred the Left fuel tank skin. This includes all the holes and the edges. Additionally cleco'd on the J stiffners and final drilled them in place, also put on the baffles.


 
Sep 22, 2023     ERFT; Final drilling left tank skin - (1.1 hours)       Category: Wings


 
Sep 20, 2023     ERFT; 16-3 ; 3 steps 1-3 - (2.7 hours)       Category: Wings
Lined off the pieces, cut, and deburred all the holes and edges of the stiffeners.


 
Sep 19, 2023     EFRT; 16-3; 3 Steps 1-7 left wing - (2.8 hours)       Category: Wings
First thing was to scratch up the flanges touching the skins. Deburred the holes. Then fluted all the flanges as so it's as straight as I can get it. Final size drilled the #40 holes and then dimpled all the #40 holes.


 
Sep 18, 2023     EFRT; 16-3; Step 5; Deburr left tank ribs - (3.2 hours)       Category: Wings
Went out of order for this one from the feedback of many builders. I deburred all the edges and holes of all the left fuel tank assembly.


 
Sep 17, 2023     Sky Design aftermarket Brackets - (4.7 hours)       Category: Wings
purchased the Sky Design engineering aftermarket brackets. The plans and installation was easy. The major problem was getting the old AN3 bolts out of the old bracket. I over torque the bolt during initial installation on one of the bolts and had a hell of a time trying to get it out. I spent many hours and methods trying to get it out. Eventually, I used a dremel tool and cut off the head, then I used a clamping vice grip to try to push it through, however, the bolt sheared in half and the bottom portion came off, then I was able to also unscrewed the top portion of the bolt. This was a lesson learned. NEVER over torque the bolts, even if you think you're barely putting any pressure on it. Now the goal is to get the aileron hinges sanded it down to size and then install that to the new brackets.


 
Sep 09, 2023     ERFT; 16-10 Step 6 thru 16-10 Step 9 - (4.7 hours)       Category: Wings
Riveted the left wing forward edge. Holding off attaching the edge to the spar until I install the Sky design engineering brackets.


 
Sep 03, 2023     ERFT; 16-8 Step 5 thru 16-10 Step 9 - (23.4 hours)       Category: Wings
Did not post for a long time. Spent 3 straight days on the forward edge modification and completed the right wing. The right wing forward edge needs to be riveted. ON both wings, the forward skin has been trimmed to size, duburred, dimpled, and primed. Attached the splice strip to the splice rib and attached that to the skin. Waiting for AD3-4.5's rivets, ran out to be able to continue to the right forward edge. Also decided to purchase the Sky design autopilot servo mount. It looks like it is better than what Garmin has to offer.


 
Jul 26, 2023     Wing Craddle Category: Craddles
Bought a few pieces of 2X6X10' and 2X4X10's. Also salvaged some pieces of wood from the shipping crate. Rented a Miter saw from home depot to make the cuts
 
Jul 23, 2023     ERFT ; 16-8 step 1 through 16-8 step 4 - (3.2 hours)       Category: Wings
Attached the leading edge to the main wing spar. Put on the template and matched drilled the #40 holes. The template took a very long time to get on and adjust to even. it is hard to bend the template in the right place to conform to the curvature of the skin. Also final sized the #40 and #19 holes on the splice strip.


 
Jul 22, 2023     ERFT ; 16-5 step 4 through 16-7 step 5 - (7.5 hours)       Category: Wings
Fabricated the forward wing cradle and made that 48" long. Worked on the nose rib by deburring all the holes and edges, also crimped the flanges so the holes align. Cleco'd the nose ribs to the forward skin.


 
Jul 21, 2023     Section 16-3, step 3 and 16-4; steps 1-4 - (3.6 hours)       Category: Wings
Completed riveting the top skins of the right wing, attached the nut plates in the inbound section as well as attached the elevator bracket in the outboard section.


 
Jul 15, 2023     Section 16-3; steps 1-3 Right wing - (5.2 hours) Category: Wings
Same at the left wing, riveted the skins on. Had help from partner to get most of this done
 
Jun 28, 2023     Section 16-4; steps 1-3 left wing - (.9 hour)       Category: Wings
Match drilled #40 holes in the outboard rib attaching the ailerons, deburred and riveted the outboard aileron hinge and rear spar per instructions.


 
Jun 28, 2023     Section 16-3; Step 3 left wing - (.7 hour)       Category: Wings
Completed the riveting of the left wing top skins with the help of my wife.


 
Jun 27, 2023     Section 16-3; Step 3; left wing - (3 hours)       Category: Wings
Replaced rivets that I was not happy with, completed riveting all the forward rivets and only thing left is the bottom section of the double overlapping holes. I will need my wifes assistance with that.


 
Jun 26, 2023     Section 16-3; Step 3 left wing - (4.7 hours)       Category: Wings
Had help from my partner riveting the left wing. Made significant progress. Did everything but the center vertical double overlap section and the forward line of rivets.


 
Jun 25, 2023     Section 16-3; Steps 1-3; Left wing - (2.7 hours)       Category: Wings
Started Riveting the inboard wing skin. Riveted the nutplates and only thing left is the top and bottom holes. Had help from wife.


 
Jun 24, 2023     Sect 16-2; Step 1 through 6 Right Wing and primed both wing skins - (9.7 hours)       Category: Wings
Worked on the right skins like I did on the left wing skins. No problem popped up. Very straightforward work. Was able to treat with prekote and primed both wing skins.


 
Jun 18, 2023     Sect 16-2; Step 6 Left wing - (3.4 hours)       Category: Wings
Deburred and dimpled the outboard wing skin. Dimpled the remaining #40 holes on the web rib flanges and rear wing spar to accept the dimpled skins. Also dimpled and deburred the J box wing stiffiners. This is for the left wing only.


 
Jun 17, 2023     Sect 16-2; Step 5,6 Left Wing - (2.2 hours)       Category: Wings
Removed all the cleco's holding the skins in place and worked on deburring the skins and the wing walk doublers. Also removed the blueing and the inside portion of the inbound skins and removed sections on the outside portion. Removed some material the best I could where the two top skins overlap. I am not worried about aesthetics for this section and wanted to not take off material or make the section uneven. So I took a few passes on on the edge with a fine metal sanding file. Completed deburring on the wing walk doublers and inboard skin. Dimpled the inboard skin. This is for the left wing only.


 
Jun 13, 2023     Sect 16-2 ; Step 1 Left Wing - (1.1 hours)       Category: Wings
Cleco'd the top wings to the left wing skeleton.


 
Jun 11, 2023     Section 15-5; Step 4 - (5.9 hours)       Category: Wings
Cleco'd together all parts for the right wing and dimpled the rear spar and associated wing rib flanges. Then cleco'd everything together and then riveted everything in place.


 
Jun 10, 2023     Sect 15-5; Step 3 - (5.5 hours)       Category: Wings
Deburred the replacement aileron hinge side bracket and primed it along with the rest of all the rear spar assembly. After the pieces are dry to the touch, put the aileron hinge side brackets together. Dimpled the holes on the spar and main rib flanges. Then clecko'd together the left wing spars to the main spar ribs.


 
Jun 03, 2023     Sect 15-5; step 1 - 2 - (3.1 hours)       Category: Wings
Cleco'd the rear spar to the ribs. Match drilled drilled the bottom row of the doublers. Machine countersink the bottom row of rivet holes on the W-1007C Rear Spar Doubler Plate

Note: I need to redo one of the hinges, one rivet got mocked up and I feel better redoing the whole thing.


 
May 30, 2023     Sect 15-4; Steps 1-3 - (1.7 hours)       Category: Wings
Match drilled the doublers and deburred all the holes.


 
May 29, 2023     Sect 15-3; Steps 1-5 - (2.75 hours)       Category: Wings
Built the inboard Aileron bracket. This step was also straightforward and got this page completed in the afternoon.


 
May 28, 2023     Sect 14-6; Step 1 - (2.3 hours)       Category: Wings
Installed bolts to upper and lower attach holes of the inboard spar ribs. Torqued it to 30in/lbs.


 
May 28, 2023     Sect. 14-5; steps 1-4 - (4.1 hours)       Category: Wings
Riveted all the ribs to the spar as per instructions. One minor gotcha. The plan calls for riveting 4 rivets on the 2nd and 3rd outboard ribs, but the facebook rv 10 board all said to rivet all 8 of the holes so that was what I did.


 
May 26, 2023     Sect 14-3: steps 5-8 Right ribs - (1.6 hours)       Category: Wings
After priming the right ribs, I went ahead and riveted all the pieces together as I did in the left ribs. After that, I cleco'd the ribs to the right spar.


 
May 23, 2023     Sect 14-4; Steps 1-2 - (2.25 hours)       Category: Wings
5/25/2023 - Upsized the holes for the conduits using the unibit for the right wing ribs. Also at removed the paper labels for the parts and cleaned the glue off with MEK. This is in preparation for prekote washing and priming for the right ribs.

5/23/ 2023 - Upsized drill the pitot/AOA the inboard tooling hole and put in the SB437-4 on the first 10 inboard ribs. Then Upsized with unibit to the largest hole for the 5/8 conduit. Then attached them to the wings in the correct order and orientation. This is only for the left wing.


 
May 23, 2023     Sect 14-3 Steps 5-8 Left spar - (1.6 hours)       Category: Wings
Riveted all the hinge bracket and torque tube hinge brackets for the left wing.


 
May 21, 2023     Sect 14-3 ; Step 4 Wash and Prime - (5.7 hours)       Category: Wings
Washed and Primed all ribs and attachment for the left wing. Also bought another set of AKZO primer and prekote


 
May 17, 2023     Sect 14-3 ; Step 4 (deburing) - (3.9 hours)       Category: Wings
Deburred all the holes on the left wing. Also used labels to attach to each wing rib and pieces so I can better identify them after I prime.


 
May 15, 2023     Sect 14-3; Step 3 - (2.5 hours)       Category: Wings
Attached the ribs to the spar. Took some time to orient the right spar properly. After the Spar was oriented the correct way. Went on to drill through the #12, #30, and #40 holes in the respective holes for the rib to spar holes.


 
May 13, 2023     Sect 14-3; Steps 1-2 - (.6 hour)       Category: Wings
Notched both 1011 L&R flanges with the two holes as well as the 1012 L&R aft flanges.


 
May 12, 2023     Sect 14-2 Steps 2-10 - (4.7 hours)       Category: Wings
Cut the angle pieces and the spacers for both wings. Also match drill the spacers per instructions until step 5. Completed this step for both wings


 
May 11, 2023     Sect 14-2; Step 1 - (4.4 hours)       Category: Wings
Completed the fluting and straightening of the rib flanges on both wings.


 
May 10, 2023     Building the Rib Flange Tool - (1.6 hours)       Category: Tools
Built the rib flange tool seen on various vans forums. I'm not a naturally handy man but I think it turned out ok.


 
May 07, 2023     Sect 14-2: Step 1 - (12.4 hours)       Category: Wings
Deburred the out flanges and then the inner rings of the wing ribs. Also smoothed out the out flanges of the wing rib. Then used a dremel tool with the cut out and deburred the inner sides.


 
May 01, 2023     Sect 13-5; Step 1 - (1.6 hours)       Category: Wings
Attached the Tie down bracket and the aileron bellcrank to both the spars.

Section 13 complete!


 
Apr 30, 2023     Sect 13-4; Step 6-11 - (3.6 hours)       Category: Wings
Fabricated the Tie down bracket. Followed instructions per Vans diagram.

Mistake:Drilled incorrectly the side and top measurement.


 
Apr 29, 2023     Sect 13-4; Steps 1-5 - (1.6 hours)       Category: Wings
Match drilled the #40 and #30 on both spars, Counter sunk both #40 and #30 for the AD3 and AD4 rivets. Attached the nutplates. One of the nutplates on the left spar did not go in well, had to drill out the rivet and upsized it to the AD4 rivet.


 
Apr 29, 2023     Sect 13-3;Step 6-8 - (3.9 hours)       Category: Wings
Riveted the Inspection Panel nut plates, countersink the nutplate holes for the #6 screws.
Prepped for priming my using MEK and qtip to remove all dirts in the holes.
Then primed the open countersunk holes on both wings using a qtip.


 
Apr 28, 2023     Sect 13-3 Step 5 - (4.9 hours)       Category: Wings
Took most of the week to countersink the fuel tank nutplates.


 
Apr 24, 2023     Sect 13-3;Step 4 - (2.3 hours)       Category: Wings
Riveted the fuel tank skin attachment nutplates on both left and right spars


 
Apr 23, 2023     Wing Spar ERPage 5: S1-2 - (2.2 hours)       Category: Wings
Attached the nut plate and doubler on the Wing spar.


 
Apr 22, 2023     Sect 13 -3; S3 - (5 hours) Category: Wings
Completed countersinking of the #40 holes on both Wing Spars. This completes the instructions for page 13-3 step 3.
 
Apr 21, 2023     Wing Spar ERPage 4 Step 1-5 - (2.4 hours)       Category: Wings
Able to primer the ER fuel tank spar doubler and countersink all the bottom left and right spar nut plate attachment holes.


 
Apr 18, 2023     Sect 13-3 Step 1-2 - (1.6 hours)       Category: Wings
Fingal sizing all #40 holes and then countersunk #40 both L & R spar nut plate attachments


 
Apr 16, 2023     Wing Spar ERpage 3 Step 1-4 - (3.5 hours)       Category: Wings
Aligned the ER fuel tank doubler to the appropriate place on both the wing spar and match drilled. Then deburred all edges and holes and ground down a portion for spar flange fitting in future attachment.


 
Apr 05, 2023     Sect 13-2: Step 5-8 - (1.5 hours)       Category: Wings
Match drill the top J stiffeners of the left wing spar


 
Apr 04, 2023     Sky Design Extended fuel tank Category: Fuel System
Decided to purchase the sky design extended fuel tanks.
 
Mar 30, 2023     Sect 13-2; Step 5-6 - (3.8 hours)       Category: Wings
Section 13 page 2, Steps 5 - 8 on Measured out the 2 sets of J stiffeners A and B, then aligned it on the wing spar 1/16 inch over the lip, then match drilled the stiffener to the spars. Completed the right wing spar. Will do the same for the left wing spar.


 
Mar 23, 2023     Sect 13-2; Step 1-4 - (3 hours)       Category: Wings
Steps 1 - 4 on page 13-2 of the wing build.

The extendernders brace and extension piece was deburred and primed before riveting in place.


 
Mar 10, 2023     Wing Kit Arrival and Inventory - (5.5 hours) Category: Wings
Over the course of a week, accepted the wing delivery and took inventory. Only 2 missing bags from Van's. Notified them and they are sending them.
 
Jul 08, 2022     Section 6 Vertical Stabilizer - (23.4 hours)       Category: Tail Feathers
Right out of the gate, made a few mistakes and had to order parts to this section up to 3 times. This took much longer than needed but glad it did. Made mistakes that taught me directions to be aware of and mistakes to avoid.


 
Jun 12, 2022     Set up Shot and bought aircraft tools from Cleaveland Tools Category: Tools
Cleaveland tools + Wood + Band Saw, Drill press, grinder, other assorted tools
 
Aug 05, 2021     Order Emp Kit Category: Empennage
Submitted down payment of Emp kit
 


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