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Entry #	Created	Title	Category	Hours	Cost	# Pictures

101	Mar 01, 2023	Fitted and drilled top skins	Wings	4	$0.00	3

 

100	Feb 18, 2023	Riveted left wing skeleton together	Wings	10	$0.00	2

 

99	Jan 26, 2023	Competed demurring	Wings	4	$0.00	1
Deburred and cleaned up all wing ribs

 

98	Jan 22, 2023	Fitted and drilled wing ribs	Wings	2	$0.00	0
This only includes main and leading edge ribs.

 

97	Jan 16, 2023	Prepare wing ribs	Wings	24	$0.00	2
Focused on demurring, fluting and straightening all the ribs for the wings. This is for the main ribs, leading edge ribs and tank ribs.

 

96	Dec 16, 2022	Rivet rear spar together	Wings		$0.00	0
Actually had to complete the right spar after receiving a replacement W-707F. One was not formed to spec. Vans shipped a replacement well before I could rivet it to the rear spar!

 

95	Dec 11, 2022	Prepared the W-707G reinforcement fork	Wings	4	$0.00	1

 

94	Dec 10, 2022	Prepped rear spar	Wings	12	$0.00	2
Deburred and drilled rear spar and doublers.

 

93	Dec 04, 2022	Installed tie-down assemblly	Wings	4	$0.00	0

 

92	Dec 01, 2022	Fitted tie-down on the main spar	Wings	8	$0.00	0

 

91	Nov 30, 2022	Create W726	Wings	10	$0.00	1

 

90	Nov 25, 2022	Spot prime and finish installing nut plates	Wings		$0.00	2

 

89	Nov 24, 2022	Attach nut plates	Wings	3	$0.00	0

 

88	Nov 24, 2022	Finish counter sink per plans.	Wings		$0.00	0

 

87	Nov 24, 2022	Counter sink for nut plates in main spar!	Wings	3	$0.00	0

 

86	Nov 15, 2022	Attach nut plates	Wings	2	$0.00	0

 

85	Nov 15, 2022	Finish counter sink per plans.	Wings	3	$0.00	0

 

84	Nov 12, 2022	Counter sink for nut plates in main spar!	Wings	3	$0.00	0

 

83	Nov 06, 2022	Identification of L/R main spars and inventory	Wings	8	$0.00	1

 

82	Oct 31, 2022	Received shipment of wing ... parts ... lots of parts!	Wings	8	$9000.00	1
Yea, spendy ... and I had to get a trailer, etc.... .. CHRISTMAS!

 

81	Jul 03, 2022	Finished last rivets on the rudder	Empennage	1	$0.00	3
The really tight rivets near the trailing edge took some time to set. Only had to use a pulled rivet on the final rivet on both sides (nearest the trailing edge). Used a home made bucking bar to get the next 2-3 rivets on the bottom and top. DONE!

 

80	Jun 19, 2022	Actually riveted the leading edge	Empennage	2	$0.00	0
After working the leading edge a bit more, final rivet set. (Lower section finally completed.)

 

79	May 25, 2022	More rolling on the leading edge	Empennage		$0.00	0
Just documenting the hours - previous post has detail.

 

78	May 24, 2022	Rolled the leading edge	Empennage	6	$0.00	0
I HATE rolling the leading edges. But even worse was the lower section of the rudder. That sucker is TIGHT if you don't do it right. It took several tries to get the two sheets of 2024 to meet without a lot of pulling. After hours of working the roll, I finally got the bend somewhat close to the profile view on the plans and the rivets were easy to set.

 

77	May 19, 2022	Riveting the trailing edge.	Empennage	2	$0.00	0
First try at video to document the process... Mostly just trying to get it to look good! Ok, I give... link works... https://live.staticflickr.com/video/52084792212/9736296492/1080p.mp4?s=eyJpIjo1MjA4NDc5MjIxMiwiZSI6MTY1MzA1Mjg3NywicyI6ImNhNDU5NzM3MjAyOGE5ZWY2N2M2YWRmYjNiODlkNjkwYWNlZjRjM2QiLCJ2IjoxfQ

 

76	Apr 30, 2022	Record keeping	Empennage	2	$0.00	7
Updated this site from notes on the plans I take while building. Attached are images of the plans and dates. Getting worried about damaging the notes as there is already water damage due to other work happening in my shop.

 

75	Apr 30, 2022	Set a few rivets	Empennage	1	$0.00	1
Waiting on sealant and a better flush rivet set. Set what could be squeezed and pulled a few blind rivets. Also sizing the alignment to the vert stab.

 

74	Apr 27, 2022	Riveted the counterbalance rib and skin	Empennage	2	$0.00	0
Also clecoed the skins

 

73	Apr 23, 2022	Finished the rudder skeleton.	Empennage	2	$0.00	0

 

72	Apr 20, 2022	Started building rudder skeleton	Empennage	2	$0.00	0

 

71	Apr 19, 2022	Rudder trailing edge prep	Empennage	2	$0.00	0
Countersunk R-916. Then primed. (Twice as I forgot to prep and the primer essentially fell off. Scotchbrite and paint thinner to prep. Then primed.)

 

70	Apr 16, 2022	Started building the rudder	Empennage	6	$0.00	0
Stopped building after a business trip. Also received an update on when the wings might ship: august- ugh. No need to rush and not interested in re-rebuilding the rudder. Finished, deburred and dimpled.

 

69	Mar 17, 2022	Installed stiffeners	Empennage	3	$0.00	0
Dimpled stiffeners and skin. Riveted stiffeners (back riveted and 3M masking tape works very well!)

 

68	Mar 16, 2022	Match drilled stiffeners… slowly	Empennage	3	$0.00	0

 

67	Mar 13, 2022	Finished stiffeners	Empennage	2	$0.00	0

 

66	Mar 12, 2022	Rudder stiffeners #2	Empennage	2	$0.00	0
After damaging one of the skins (R-901-R) I received a new one from VAns wit stiffeners and more rivets. Today began breaking the stiffeners apart.

 

65	Mar 11, 2022	Trim cover plate	Empennage	8	$0.00	1
Well this one step took at least 8 hours over several weeks of frustration! Alignment of the motor to properly access the trim tab without taking out metal from the elevator skin OR bending the pushrod was the goal. First try was accomplished after measuring and then remeasuring the assembled tab. Drilled and riveted. Nope. Pushrod would rub the skin. Formed a new cover from scrap aluminum. Easy enough. With a cardboard model of the motor and pushrod I remeasured everything. Drilled and assembled. Nope. Ugh. Formed a third cover. Repeat with all lessons learned. Riveted everything together. NAILED IT. A month later I had the chance to view an RV7a that has been flying for years. Yea, I did better! But what a pain…

 

64	Mar 10, 2022	Removed flange on h stab	Empennage	3	$0.00	1
Tedious job. - installed elevator - measure and mark - remove elevator - trim metal - install elevator - ugh- repeat And then repeat for left elevator..

 

63	Mar 06, 2022	Installed rod end bearings	Empennage	4	$0.00	0
That was frustrating! (Hitting the hole while aligning everything while standing on one foot. That was fun! That is- seeing something looking like a functional airplane assembly!

 

62	Mar 05, 2022	Rolled leading edge	Empennage	5	$0.00	0
Well, looks mostly correct. I feel like I should do a practice elevator before doing the final product :( But, it is just cosmetic. Pulled the leading edge causing a little bending near the spar. Not much and appears I'm not the only one. Most of the roll looks pretty good though.

 

61	Mar 03, 2022	Finished trim tab	Empennage	1	$0.00	0
Set blind rivets and hinge pin.

 

60	Feb 26, 2022	Riveted the tab and installed	Empennage	5	$0.00	1
Assembled and riveted the tab. Riveted the hinge to the elevator.

 

59	Feb 25, 2022	Finished prepping the tab	Empennage	2	$0.00	0
Trim, finish, deburr, dimple .. oh my…

 

58	Feb 24, 2022	Drilled the tab spar	Empennage	2	$0.00	0

 

57	Feb 22, 2022	Continuing trim tab	Empennage	2	$0.00	0
Bent the tabs. Drilled the tab horn.

 

56	Feb 21, 2022	Completed the trailing edge bend on the trim tab	Empennage	1	$0.00	0

 

55	Feb 13, 2022	Riveted the left elevator	Empennage	5	$0.00	0
Completed the left elevator. Still need to do the trim motor and tab.

 

54	Feb 10, 2022	Riveted the counter balance skin	Empennage	1	$0.00	0
Just a little work today.

 

53	Feb 08, 2022	Riveted the elevator skeleton	Empennage	2	$0.00	0

 

52	Feb 07, 2022	Bender the elevator tabs.	Empennage	2	$0.00	0
Well, it turned out ok, but could have been a little better if I would have left well enough alone. Once the blocks are removed- stop hammering the metal! It is a little less than straight, but I may be the only one that notices….

 

51	Feb 05, 2022	Preparing the trim spar	Empennage	2	$0.00	0

 

50	Feb 01, 2022	Deburred and dimpled the left elevator	Empennage	4	$0.00	0

 

49	Jan 28, 2022	Finished drilling the left elevator	Empennage	5	$0.00	0

 

48	Jan 27, 2022	Completed the right elevator	Empennage	2	$0.00	1

 

47	Jan 26, 2022	Riveted the skeleton together.	Empennage	2	$0.00	0

 

46	Jan 25, 2022	Finished left elevator prep	Empennage	1	$0.00	0

 

45	Jan 24, 2022	E709 prep- left elevator	Empennage	1	$0.00	0

 

44	Jan 21, 2022	Left elevator prep	Empennage	2	$0.00	0
I started the elevator build by performing the same steps on left and right elevators. Today the focus is on the right elevator skeleton.

 

43	Jan 20, 2022	Drilling counter balance for elevators	Empennage	3	$0.00	0
This includes the rib and the lead weights. Using a little oil did seem to help the bit not gum up.

 

42	Jan 19, 2022	Working doublers and reinforcing plates	Empennage	2	$0.00	0
Continuing work but easy compared tot he trailing edge.

 

41	Jan 19, 2022	Bent trailing edge of the elevators - that was a “job”	Empennage	3	$0.00	0
Anyone else doing this step- go slow. Easy to get odd shapes on the trailing edge near the stiffeners. With some work one can make it look better ….

 

40	Jan 17, 2022	Drilled and back riveted stiffeners	Empennage	3	$0.00	0

 

39	Jan 14, 2022	Finished stiffeners	Empennage	2	$0.00	0

 

38	Jan 13, 2022	Started elevator - began building the stiffeners	Empennage	2	$0.00	0

 

37	Jan 08, 2022	Riveted vert stab skin - completed vert stab!	Empennage		$0.00	1

 

36	Jan 07, 2022	Riveted the vert stab skeleton	Empennage	2	$0.00	0

 

35	Jan 06, 2022	Clecoed the vertical stab skeleton	Empennage	1	$0.00	0

 

34	Jan 05, 2022	Finalized drilling vertical stab	Empennage	2	$0.00	0

 

33	Jan 04, 2022	Drilled the vertical stab skin	Empennage	2	$0.00	0

 

32	Jan 03, 2022	Continuing the vertical stab skeleton	Empennage	2	$0.00	0

 

31	Dec 31, 2021	Building the rudder skeleton	Empennage	8	$0.00	0
Back riveting was fun! But messed up when I didn't have the plate properly place once. Just a cosmetic dent. I'll have someone take a look, but looks better than hangar rash on some I've seen. But this is a control surface, so I'll get that second set of eyes. Also started building the rudder skeleton. Lots of pieces coming together.

 

30	Dec 30, 2021	Fitting the Stiffeners to the Rudder skin	Empennage	2	$0.00	0
Deburred and dimpled the rudder skins.

 

29	Dec 29, 2021	Fitting the Stiffeners to the Rudder skin	Empennage	2	$0.00	0
Drilled all the stiffeners

 

28	Dec 23, 2021	Fitting the Stiffeners to the Rudder skin	Empennage	2	$0.00	0
Sized the stiffeners to match the skins per plan.

 

27	Dec 22, 2021	Drilling the V Stab	Empennage	4	$0.00	0
Mostly match drilling the spar - and then spent a fair amount of time realizing I really was sent 3 HS-706 tip ribs and zero VS-706 tip ribs. Will call Vans to get a part sent. I was hoping it was just the same part, but not the case - different dimensions.

 

26	Dec 19, 2021	Drilling the V Stab	Empennage	2	$0.00	0
Mostly identifying parts, pulling blue plastic and clecoing everything together.

 

25	Dec 17, 2021	Riveting the H Stab	Empennage	2	$0.00	1
First real go at blind rivets. Easy enough - but getting them in place was not much fun. And the first part is done!!

 

24	Dec 15, 2021	Riveting the H Stab	Empennage	2	$0.00	0
Finished the right side and riveted on the rear spar - up-side-down. Grrr... well, I must have things pretty square as it went on easily! Oh, well, symmetric part an only the "up" arrow I drew now points "down".

 

23	Dec 14, 2021	Riveting the H Stab	Empennage	3	$0.00	0
Got most of the right side done - a little easier with the PC on the skin trick.

 

22	Dec 12, 2021	Riveting the H Stab	Empennage	6	$0.00	0
Well, that was VERY FRUSTRATING getting the first few rivets on the middle rib - flush and ... required several tries. Even had to drill out the first go at it. The final solution was to take and old PC and lay it on top of the skin to keep it from pulling the first rivet out as I was working the second one.... but I got all the rivets in - and the rib flange is flush against the skin. The process was not fun, but the result looks a little like part of an airplane! Won't be the prettiest, but looks a lot better than some of the airplanes I've rented. Left side riveted!

 

21	Dec 08, 2021	Riveting the H stab	Empennage	2	$0.00	0
Got more TV watching then riveting, but did get a few ribs riveted.

 

20	Dec 07, 2021	Riveting the H Stab	Empennage	2	$0.00	0
Riveted the front spar together.

 

19	Dec 04, 2021	Riveting the H Stab	Empennage	2	$0.00	0
Just got the hinge brackets together. I will need to buy a small torque wrench as the one I have is too big for these small bolts.

 

18	Dec 01, 2021	Riveting the H-Stab	Empennage	3	$0.00	0
Riveted the rear spar parts together. Got a couple of "smilies", but nothing terrible. I gotta remember to clam everything down as that aluminum moves around with the rivet gun going!

 

17	Nov 30, 2021	Preparing parts for assembly	Empennage	6	$0.00	0
More time was spent over the week finishing, deburring, and dimpling. Not sure all the time was tracked. Kind of a turn on the TV and pick a part to work on. Also primed the non alclad parts. HS-609, HS-710, and HS-714. Two coats of self etching primer, black.

 

16	Nov 16, 2021	Drilling the H Stab	Empennage	2	$0.00	0
Completed drilling the right side of the H stab!

 

15	Nov 15, 2021	Drilling the H stab	Empennage	2	$0.00	0
Finished the left side and started the right side.

 

14	Nov 14, 2021	Drilling the H Stab	Empennage	4	$0.00	1
Many steps on the left side of the H stab - fitted and drilled all the ribs. CLECOs look cool once in place.

 

13	Nov 13, 2021	Drilling h stab	Empennage	6	$0.00	0
This was a lot of fun - actually mating a skin to the frame to fit all the ribs in place. Actually looking like something "aircraft like".

 

12	Nov 12, 2021	Preparing ribs	Empennage	2	$0.00	0
Most of the ribs were nearly perfect - but not quite. Very little fluting was needed but did use a pair of needle nosed pliers to get each flange perpendicular to the rest of the rib.

 

11	Nov 10, 2021	HS-411 assembly	Empennage	2	$0.00	0
Waited to get some primer before starting on the VA-146. I'm guessing it isn't pure aluminum. Primed and riveted together the assembly.

 

10	Nov 07, 2021	Preparing ribs	Empennage	3	$0.00	0
Dimple and countersink for the flush rivets holing the front spar together. Odd, but Im guessing something goes here later that needs more clearance. Notched rib to fit around the spar.

 

9	Nov 04, 2021	Match drilling	Empennage	1	$0.00	0
Match drilling ribs for H stab

 

8	Nov 03, 2021	HS710	Empennage	2	$0.00	0
Tapering ends of the HS710.

 

7	Nov 02, 2021	Match Drill Doublers	Empennage	1	$0.00	0
Match drilling spar doublers -

 

6	Nov 01, 2021	Front Spar	Empennage	1	$0.00	0
Bending down tab as specified in plans. Not a lot of work - but keeping momentum.

 

5	Oct 31, 2021	Front Spar	Empennage	4	$0.00	0
Match drilling the front spar for the H stab

 

4	Oct 30, 2021	Elevator hinge brackets	Empennage	2	$0.00	0
Continuing the build with 2 hours most nights. Completed the elevator hing bracket match drilling.

 

3	Oct 28, 2021	Prepared HS-609PP	Empennage	2	$0.00	1
Using scotchbrite wheel, cleaned up the reinforcing bar per plans. Then clieco'd the bar to the rear spar and match drilled using #30 drill bit per plans.

 

2	Oct 27, 2021	Prepare HS-609PP	Empennage	2	$0.00	1
Following first instruction to prepare the reinforcing bar HS-609PP. - Numbered each item for (re)placement as items are worked - used scotchbrite wheel to prepare the edges - ends rounded to 1/4 inch - worked edges of bar to lay flat near HS-603PP - per instructions. Aluminum dust! Will get PPE...

 

1	Oct 26, 2021	Received and inventoried	Empennage	2	$2440.00	1
Empennage arrived, unpacked and inventoried. - One rib missing VS-706 - One extra rib HS-706 - One bearing missing MD3616M Also looks like the label are a little different in the BAG 616-PC sub-kit. looks like the correct parts, but the labels are different than what is on the documentation (e.g. HS-411BPP-PC is labeled as HS-411PPC)

  ------------ -------------- ------------- Totals322    $11440.00    37