RV Blog

Time to rivet the last skin

Sun, 22 Jan 2012 20:46:08 -0800

It has been a very long time since the last time I was riveting a Skin on the airplane. Today was the start of the last time. I starting working on the forward skin. That means I can’t think of anything else to do inside the cockpit. Now that this skin is getting riveted on, anything behind the panel will mean crawling in, upside down, and working in a very uncomfortable position. It also means that I am moving on to those finishing task. Once this is done, I can start fiberglassing the windshield. Once that is on, I can put the wings on and start the engine. Oh, did I mention I also put brake fluid in this weekend? Yes, the brakes are also done. Hmmmmm, things seem to be falling into place. Maybe I will fly this year.

I would like to thank Keith for helping with the rivets today. John has moved off to Ohio, so I had to recruit a new helper. Thanks.

Moving on to final fittings

Mon, 2 Jan 2012 16:53:42 -0800

Today I started the process of fitting the windshield. After reinstalling the forward skin with clecos, I was able to mount the windshield. I did this so I could mark on the skin the line where the windshield connects. Later a flat black spray paint will be applied inside that line. I also test fit where the compass and GPS antenna will be mounted. Put it together, take it apart. I must be building an RV. At least I am working on things that are on the final assembly list. Whoo Hooo!

New Years Day Update

Sun, 1 Jan 2012 11:24:34 -0800

Will this be the year the plane is finally finished?

Who knows. I have been saying the plane will be done next year for the last three. Yet here we are on new years day 2012 and the plane is still just a project. Yes, it gets closer everyday. Yes I can see light at the end of tunnel. Yes I believe it should be done this year. Yes, I said the same thing last year at this time. Only time will tell.

December Update;
- All air lines routed in the fuselage (Pitot, Static & LRI). I will have wing root connections for the air lines. For now all the lines inside the fuselage are done
- Tail cone wiring run is secured in conduit
- Tail cone static air line connected
- Auto pilot pitch servo connected and tested for proper operation
- Aileron trim system installed
- Wiring behind panel secured

List of major items left to complete
- Install last forward skin over panel and wiring (started this weekend)
- Install windshield (largest single item left on the list)
- Re-install wings for final assembly
- Install wing tips, aileron servo, navigation lights, heated pitot, VOR antenna, stall warning and LRI in mounted wings
- Charge braking system with hydraulic fluid
- Test start the engine
- Schedule final inspection with DAR
- Go Fly!

November Update

Thu, 24 Nov 2011 21:42:23 -0800

Yes, it has been a long time since I managed to write up a quick report on my activities. I have been getting some work done, but progress always seems slower then I would like. Anyway, here is a list of the items completed since my last post.
- All engine sensor wires have been secured
- Engine oil breather line installed
- Engine fuel pump overflow line installed
- All firewall forward systems complete
- The engine is ready to fire up and test, once the prop and wings are installed
- My third fuel pump was installed. It’s done and ready for pressure and flow testing
- Air lines for Pitot, Static and LRI are being routing from the wing roots to the back of the panel

A weekend of wiring

Sun, 2 Oct 2011 21:32:36 -0700

Once again I have to report slow progress. Just not enough time in my schedule to get to the airport. So when I am there, I have to make hay well the sun shines! This weekend I got busy securing the wiring in the engine compartment. It is a big job as there are lots of wiring runs. The book says that all wires should be secured every six inches, and have a twist tie in the middle of the open space. Turns out that requires a lot of creative tinkering to figure out how to route and re-route the wires to make that happen. After working all weekend, I have secured the wires on the left side of the engine. In this photo you can see the adel clamps used to secure the wiring bundles to the engine mount, with the heat resistant tefzel twist ties in between each clamp. I also tried to keep the high voltage spark plug wires separated from the sensor lines.

Wiring Engine Sensors to EDM

Sun, 28 Aug 2011 13:46:53 -0700

Ok, lets be honest. The last two months have seen almost no progress on the plane. I have been swamped at work, and after 5.5 years my wife and I have been finding other things for me to do on the weekends. All of witch is fine by me, no complaints. The plane is getting closer and will be done some day fairly soon. It really doesn’t matter if it is this year or next. It is close and it will get done. This weekend I did manage to add a few wiring runs from the engine sensors to the TruTrak Engine Data Monitor (EDM). All of the CHT, EGT, Tach, Fuel Flow, Oil Pressure, Oil Temp and Fuel Pressure sensors are wired and installed. In the engine compartment I still have to work on a relief valve that gets installed on the mechanical fuel pump, the oil breather tube and the manifold pressure sensor. That it. After that it will be time to start finishing up. Yea!

Hangar Move In

Sun, 7 Aug 2011 17:26:14 -0700

The past six weeks have had NO WORK performed on the plane. I have been traveling non stop for work, and just have not had enough time to get up to Cable. On top of that, Cable called and said, are you ready to move into your new hangar? Of course the answer was YES! In this picture you can see my plane tucked into my new T hangar at Cable airport. No more shared spaced in the EAA hangar. Now I can put the wings on and finish the plane.

Engine Wiring underway

Sat, 18 Jun 2011 19:41:54 -0700

My A&P mechanic friend came over again this afternoon. We started running all the Eagle EMS wiring runs. CHT, EGT, Spark Plugs, Speed Sensor and Fuel Distribution. It was a busy day. As this photo shows, the wiring runs have been started, but none of them have been tied down and secured yet. Trying to get everything in position before I start bundling and clamping down with adel clamps and twist ties. My estimate is about 75% of the engine work is now done. Ron will come back one more time in two weeks, which should be just enough time to finish off all the engine work. After the wings and windshield get installed, it will be time to start up the engine.

Fuel and Oil lines connected

Sun, 22 May 2011 18:25:58 -0700

This weekend saw some serious progress in the engine compartment. I hired a certified aircraft mechanic to help me install the oil and fuel lines. I wanted to make sure they were done correctly, so paying a pro a few dollars to help me seemed like a great idea. I know I could have done it all myself, but when it comes to the life blood of the plane (Fuel & Oil), I really wanted someone who knew what they were doing. A couple of hours with Ron helping and the oil cooler, oil temp, fuel pressure and main fuel line to the distribution block are all installed. Ron is going to come back for one additional session to help me get the remaining engine sensors installed (EGT, CHT, MAP, etc.). This plane is looking better every day. I feel confident that I will be flying by the end of the year!

Alternate air supply door

Sat, 30 Apr 2011 18:43:01 -0700

I have seen several photos on the net showing the VANS alternate air supply door with cracks. I decided to follow the advice of some other builders and make my own alternate air supply door. This is a .032 skin, a middle .063 door and U shaped track, toped by another .032 skin. I still need to create an angle bracket that the cable can hook to. I am adding a .032 plate to the bottom of the FAB. This door will be riveted to that plate. When done I am hoping to not have any parts that are being stressed by vibration. I will also not have anything that can get loose and be sucked into the engine.