Daniel's RV-7

FUSELAGE IS HERE!!!

Daniel — Sat, 24 Jul 2010 05:35:27 +0000

8 weeks after ordering – The fuse showed up! Only problem is I can’t start it just yet. I agreed to help a friend who is building a -7A, and his -6A was a QB, so he doesn’t know how to build the wings, and wanted my help. So I agreed to help him out. I hope to be finished with his wings sometime in August and then I’ll tear open my fuse crate and start inventorying! Can’t wait.

And this is just a picture I took that night… thought it turned out kinda neat:

Right Wing Aileron Brackets & Braces…

Daniel — Sun, 04 Jul 2010 05:02:35 +0000

No pics today, nothing really to show. I got to the hangar this morning and started with the flap brace. Got it match drilled, deburred, dimpled, primed, and installed. It was an interesting task though, as I messed up and already put the top and bottom skin on. I don’t know how I forgot about this, but I did. There’s a guy at the airport that hangs out there alot named Mervin – He helped me with this task. I had to reach all the way in through the inspection hole, through the adjacent rib, and up to the rear spar to buck these rivets. We checked to make sure the shop head was correct using a boroscope. It took some time, but we got them all done. I also made the aileron brackets, and got them installed as well.

Due to the high level of humidity, come 4 o’clock, I had enough. Closed up shop and went home! Tomorrow, I’m going to get the bellcrank and pushrods in the right wing. I also plan on making some kind of jig to center the ailerons so I can start on installing the flaps! Till then, goodnight!

Right Wing – Bottom Skins…

Daniel — Sun, 20 Jun 2010 00:49:19 +0000

Started riveting the inboard bottom skin on the right wing today. This is a pain in the ass, but not as bad as some make it sound. I did the entire thing myself in about 4 – 5 hours. If I had another set of hands there to help, it would have been done in less time. Im going to try and do the left wing tomorrow morning…

Bottom skin primed, and wing on the workbench with the skin sitting on it

I used tape to help hold the skin back. It got much easier as I got out of the wing walk area
and got closer to the ouboard end.

The finished bottom skin.

Pitot & Angle of Attack Lines…

Daniel — Sun, 20 Jun 2010 00:33:11 +0000

I finally opened the SafeAir 1 Pitot-Static & AOA kit today. This has been sitting on my shelf for quite some time. I have yet to order a pitot but did go ahead and mount the pitot mast. The lines are color coded – Green for the pitot, and blue for the AOA. There is also a white line in the kit that will be used for the static ports in the fuselage. The lines pass through all the ribs using snap bushings.

Aileron Pushrods & Bellcrank…

Daniel — Sun, 13 Jun 2010 22:26:51 +0000

I finally got around to making the pushrods and getting the bellcrank installed. It’s kinda fun making the pushrods… I used a little self centering vice from Harbor Freight on the drill press and it worked out quite well. The pushrods are really pretty self-explanatory. Just measure everything out, leave about 1/32″ more just to accomodate for the blade thickness and to leave enough to clean up the ends.

Main Pushrods, cut to length, prime, install threaded end, and rivet.

And here is the small pushrod that goes from the bellcrank to the aileron attach bracket.

Right Wing – Top Skins…

Daniel — Sun, 13 Jun 2010 00:04:42 +0000

Today I started on the top skins for the right wing. I tried a little experiment, using scotchbrite pads in my angle grinder to deburr all the rivet lines. While it WAS a lot faster than the traditional deburr method, I just don’t like the look of it. And yes the skins will be painted, but still… it bothers me. So I won’t do it again!

Right Tank – LEAK FREE!!

Daniel — Mon, 31 May 2010 17:20:07 +0000

Well, alot has gone on over the past few days or so… I finished sealing the fuel tank, let it cure for a few days, and then brought it back to the apartment to pressure test (since the apt is a controlled environment). I used the water column method again, and had a little trouble at first… I kept loosing pressure over a few hours. I discovered it was one of the hose clamps… it put a hole in the tubing I was using for the water column. Replaced it, tested again, and I am happy with the results. THANK GOD FOR NO LEAKS ON THIS ONE!!! So now things will move along at a better pace since I’m not having to play with proseal anymore. I must say, I have grown quite fond of how that stuff smells… weird I know. Anyways, im relaxing the rest of the day… A big thanks to all the military men and women who have given the ultimate sacrifice for our country. As for the rest of you, happy Memorial Day weekend!

End Ribs completed:

Fuel Drain installed. Make sure to put proseal on the threads, but NOT on the o-ring that seals the plunger.

Rear Baffle close-up… Blobs of proseal on shop head of rivets. Also, hole in rear baffle for the fuel sender.

And the whole package!

Right Fuel Tank – Rear Baffle…

Daniel — Wed, 26 May 2010 15:47:08 +0000

Pulled a late night tonight. Didn’t get home till after midnight. But I did get the rear baffle done and cleaned up for the most part!

A quick picture I snapped… My truck at the airport, right after a storm.

Ok now for the serious stuff… Pics before starting that night, All I had to do was seal/rivet the rear baffle in; simple right?

Fuel Tank Plumbing 2…

Daniel — Sun, 23 May 2010 19:50:41 +0000

I got another -6D fitting! Got the flop tube in, vent, and fuel return line. Torqued everything, and prosealed the connections going through the rib. I am at the point now where all that is left is to install and seal the rear baffle and mount the sending unit. I’m looking forward to being finished with this tank. Hasn’t been near as much of a pain as the first one tho!

Right Fuel Tank Plumbing…

Daniel — Thu, 13 May 2010 22:40:00 +0000

Very light duty work today… I finally had a surgery to correct a medical condition that I had been putting off for quite some time, so the past week has been pretty slow… not much I can do laying in bed. Today I ran the vent line, the fuel return, and put the flop tube in… I didn’t torque these and Im waiting to see if I can find another AN833-6D fitting for the return line cause I messed the threads up on one by dropping it. I went ahead and torqued the flop tube to another fitting and safety wired it. I didn’t have my digital camera so I snapped a pic with my iPhone: