Started Ailerons

I started building the Ailerons this past weekend. I stayed dry in the shop as it rained almost the entire weekend. I small break in the weather on Saturday night allowed me to sit outside and cut all the small stiffening angles while smoking a large slab of beef on the grill. A nice evening out on the back back patio, propping my feet up, cutting the 32 small angles out, and throwing extra wood on the fire to keep the smoke rolling....as if building an airplane wasn't enjoyable already.

The ailerons are a welcome change from the drudgery of the fuel tanks. Cleco, drill, deburr, rivet...no mess. It's nice. The ailerons require an extra check here and there to be sure the correct parts are in there correct places. The skins aren't exactly the same and you need to be sure you're using the correct side up, etc. I clearly marked the skins and all the parts to reduce the confusion. When I first clecoed all the parts together, as the instructions state, on a flat table, the aileron was out of alignment, kinda wavy. I set that one aside and worked on the second. This time I clecoed the trailing edge first and then the nose skin and everything lined up perfectly. Sometimes the methodology in the instructions are not the best. I disassembled the first aileron and re-clecoed in the same manner and it completely straightened out. Drilled both parts and called it a night.

Saturday 4.5hrs
Sunday 4.5hrs
Monday 1.25hrs
All hours to ailerons.

Placing the stainless steel tube counterweight into the leading edge of the ailerons.

Wrapping the leading edge skin around the assembly was somewhat difficult work. A little grunting and a shove got the holes lined up.

My deburr helper, until....

 

 

....deburr helper number two got fussy!

Backriveting the stiffening angles onto the aileron skins.

Visiting Daddy in the shop to check on the progress of her airplane.

Ailerons clecoed and drilled. Ready for deburr and dimpling.

Completed Structure Overview (626hrs)

Time for an update to the big picture. I'm leaving the Fuel Tanks as "in work" until they get tested, so those are still highlighted red. And I'm starting on the ailerons tomorrow, so I went ahead and highlighted those as "in work" as well.

626 hrs Total Time Building
185.5 hrs of the total belong to the Wings (includes tank time)
75.25 hrs solely to the Fuel Tanks
440.5 hrs is a mixture of tail and fuselage, both still have work to be done on them

 

As always blue is completed and red is in work.



Finished Fuel Tanks

Well.....I finished building the Fuel Tanks. I still need to test and then install them. But, for now, I'm done with Proseal, MEK, and the slow process of tank building. I don't feel as excited or relieved as I thought I would be when I finally finished these things, maybe I'll feel that way when they are tested and installed. Other than being a complete PITA, the tanks assembled in a straight forward manner without much head-scratching. The one hang up I had with the tanks was the very last step when installing the Fuel Drain valves. In my mind the valves should have screwed all the way in, when in reality they leave about a 1/4" of thread exposed and kinda stick out from the tanks (sorry no picture). So, in an effort to monkey torque these in I galled up the threads a little....oops. I still have plenty of thread engagement and I installed them with Proseal so hopefully no leaking issues....there is always something that leaves you nagging in every section.



Saturday April 20th - 3.25hrs - Finished Vent line install, installed fuel sending units, finished fillet seal edges on last rib.

Sunday April 21st - 6.25hrs - Scuffed baffle, spread Proseal on baffle, riveted baffle, riveted mount brackets

Tuesday April 23rd - 1.5hrs - Finished sealing baffle and shop head of rivets.

Wednesday April 24th - 1.5hrs - Cleaned shop and wiped down tools with MEK to remove all the Proseal. I'm counting this as Fuel Tank time since the tools only required that level of cleaning because of the tanks.

12.5hrs to Fuel Tanks = 75.25 hrs Total Fuel Tank Time

LH Fuel Level Sending Unit Installed. Notice the extra bend near the float I needed to create so the wire wouldn't hit the bottom of the tank.

RH Fuel Level Sending Unit. Same as Left.

 



Getting ready to install aft baffle.

Fuel Tanks complete!

 

 

I slid the fuel tanks under the fuselage for safe storage. In a few weeks, when I know all the Proseal is cured, I will test them and mount them to the wing.

 

My Picture in Flying Magazine!

I was really excited to buy the May issue of Flying Magazine! They asked for a high res image of the picture shown below and featured in this November 13th post. Of course I submitted it to them and was told they "will most likely use it". I eagerly waited for the issue to hit the stands to see if I made the cut. I am honored to find they used it to fill the page!

I want to say Thank You to Flying Magazine in making my building experience just a little bit cooler.

 

 



Tube Flaring - Fuel Tanks #11

April 17th 1.25hrs
Obviously this post is a little behind, but I've been busy, and secretly I'm further along than this post shows....but that's for another post on another day.

I flared the vent lines using this tool:

It's a Parker 212FB Rolo-Flair 37° Manual Rotary Flaring Tool and it works great! It comes with a small writeup of instructions, although, it's rather intuitive. Play around with the thing for a few minutes and you're a pro.

I checked the flare against this spec:

and it was dead on....a perfect flare.

I followed this spec for torque:

You can easily work on the vent line with the Inboard Rib in place.

Nice flare.

I cleaned the inside of the tanks with Acetone and inspected the seals and added Proseal anywhere I thought necessary.

Random pic of the baby.

APPLESAUCE!

Fuel Tanks Post #10

If my counting skills are correct I think this is the 10th post that deals with Fuel Tanks. Last night was a productive evening. I went through the tanks and applied extra sealent where I thought it needed it. I got the last rib prosealed and riveted in place. The vent line is cut, with my new cutting tool, and slid into place. The flare tool arrives today so hopefully tonight I can knock that out. If all goes well I might be finishing these tanks this weekend!

Monday 15th - 1.25hrs - Sealed tanks, started bending fuel sending unit wire

Tuesday 16th - 2.25hrs - Sealed tanks, riveted last rib

 

3.5hrs to Fuel Tanks = 61.5hrs total on Fuel Tanks

Fuel Tanks and Flap Fairing

I've been driving an old truck for the past decade. The kind of truck that every component around the engine is new. You name it, I probably replaced that part on this truck at least once. As the truck approached 200,000 miles it just didn't run like it used to, so I stopped using the AC or else it would just not run at all. Well, eventually the AC just wouldn't run at all. So, I drove around for years without an AC....in ALABAMA. Yeah it's hot. I really needed a new vehicle but never wanted to spend the money. Then Ayla was on her way and this gave me the excuse I needed to just buy a new car. Of course my wife gets the new car and I get her hand me down car....so what, at least the AC works. Until I started driving it, I fired up the AC last week and nothing but hot air...go figure. Well, this AC I'm fixing. Busted out the tools on Saturday, pulled a vacuum on the system, added leak dye, and now she's icy cold.

After fixing the car's AC Saturday morning I went to work on the Fuel Tanks. Yay more fuel tank work! I'm getting so close to finishing these I can smell it, and it's not just the MEK fumes.

--
I forgot to post a little work I did last Monday night.
Monday 8th - 0.75hrs on the Flap Gap Fairing. Deburred and dimpled skins. The dimling is fast work with the pneumatic squeezer.
--

Saturday 13th - 2.5hrs on Fuel Tanks. Clecoed J-Channel and Attach Bracket eith Proseal, wiped down and scuffed edges of ribs for baffle install later. The J-Channel sliding into position wasn't too bad. I really see why you need to smear the Proseal on the tank skin first, it would be a real mess otherwise.
                       - 1.0hrs on the Flap Gap Fairing. Dimpled and riveted onto skin.

Sunday 14th  - 4.5hrs riveted all the above Prosealed stuff together.

7.0hrs to Fuel Tanks = 58hrs total on Fuel Tanks

OK kids this is the advanced Proseal application class....using an inspection mirror.

Fuel Tank attach bracket riveted in place.

 

 

Flap Gap Fairing clecoed in place.

Shop Picture on Flying Magazine Site

There is a picture of my shop on the Flying Magazine Website! They put together a photo gallery of RV builders titled "RV Aircraft: A Builder's Journey" featuiring many great guys and their projects. I'm honored to be one of the pictures.

They emailed me to ask permission to put a picture of me in the magazine as well! Cool stuff. The article should be in the May issue...we'll see. I'll make another post if it happens.

Here is a link to the Flying Magazine Photo Gallery. My shop is picture number 16.


...in time I'm sure this link won't work anymore so I'm going to post a screenshot of the web page, a fun thing to add to my builder's log book....

Fuel Tanks and Lower Skins

A beautiful weekend here in North Alabama to work on your airplane. Of course, I had more work on the fuel tanks with that great stuff we call proseal. I was able to use the pneumatic squeezer on all of the rivets of the outer ribs. Although, the process is still really slow this was an improvement over riveting.
FYI
An example of all the steps involved on the fuel tanks for each rivet:
1. Remove prosealed cleco
2. Drill out hole to clean out proseal
3. Twist MEK soaked countersink in hole to really clean it out.
4. Wipe away surface of old proseal
5. Squeeze a little proseal in the hole
6. Carefully pick up only one rivet using a sticky punch dipped in proseal
7. Insert rivet and press firmly
8. Smear proseal flat
9. Set rivet and move on to the next one
You see.....it's just slow.

Since this fuel tank proseal stuff is so slow I decided to start on the wing's lower skins. This is some work that I can do for an hour here and there throughout the week. I'll get back to the time sucking fuel tanks next weekend. I finished up Saturday saying "you know these fuel tank things aren't too bad" then I began to work on the lower skins...no proseal, no 9 steps, etc....I realized the joy of building that I had been missing. Wow...look how fast I can go from one step to the next! No mess! This is great! By Sunday I was saying "you know these fuel tank things really do suck".

Friday 5th - Prosealed and clecoed outer ribs, Cap ring, Fuel Drain, other parts
  2.5hrs
Saturday 6th - Riveted all the parts clecoed on Friday
  4.75hrs
Sunday 7th - Started lower wing skin section with the flap closeout panels.
  1.75hrs

7.25hrs to Fuel Tanks = 51hrs total on Fuel Tanks

View looking down into the fuel tank with filler tab clecoed in place.

Outer ribs riveted and prosealed.

Inner rib and fuel drain clecoed and prosealed.

Tools

I had a blog reader ask me about which tools I purchased and it made me realize that I never discused my tool decision. I compared many different tool kits you can buy for a new RV builder and decided that Planetools.com was the best purchase. They have quality tools and the quantity you get for the price was the selling point. So I put together the chart below when I was making my decision on which tool company and kit to go with.
First Column...Vans Aircraft suggested tool list. This is a general list...a minimum to get by.
Second, Third, and Fourth Column...Tool Kits from each supplier
Fifth Column....shows what an individual did by piecing together his tools one purchase at a time. He purchased a lot of used tools off ebay or local builders. This process might be a little cheaper but you are spending a lot of time searching for the tools and then paying shipping costs. The tools that are used may or may not be complete or usable i.e. missing parts etc. Is there any damage to the tools? Is the tool supposed to be like that? (don't know never used one) I wouldn't mind buying used tools on a pinch but as a new builder I wanted an entire set that was undamaged and complete.

Also, as a side note, I started to price the individual tools to see if the kit was really worth it and I came to find out it was. Sorry, I don't remember the actual numbers, this was over a year ago, but I know that I wouldn't have bought the kit if it wasn't worth it.

The Plane Tools Kit

		$2,390	$2,354	$2,209	$1,800
Tool List	Vans general Suggested List	Plane Tools	Aircraft Spruce RV Builder	Cleaveland	Individually Purchased
C-Frame Riveting Tool / Dimpler (Handle)		1			1
C-Frame Riveting Tool / Dimpler (Hammer)	1		1	1
Pneumatic Rivet Squeezer		1			1
3" C-Yoke Installed on Squeezer		1			1
Adjustable Set Holder - Optional		1			1
Hand Squeezer 3" Yoke	1		1	1
3600 RPM Palm Air Drill	1	Sioux Opt		1
4500 RPM Air Drill			1
3X Rivet Gun	1	1	1	1	1
Beehive Spring			1
EZ change Spring for straight rivet sets	1	1	1		1
EZ Change Spring for flush sets	1	Snap On
Swivel and Air Flow Restrictor	1	Fine Prec	1	1	1
1" Diameter Flush Rivet Set	1	Snap On	1		1
3/32" Cupped Rivet Set 3.5" long	1	Snap On	1		1
1/8" Cupped Rivet Set 3.5" long	1	Snap On	1	1	1
3/16" Cupped Rivet Set 3.5" long	1	Snap On			1
1/8" Double Offset Rivet Set	1	Snap On	1	1	1
Back Rivet Set	1	Special	1	1	1
Mini Bucking Bar 1lb	1			1	1
Anvil Bucking Bar 1.9lb	1		1		1
Footed Bucking Bar 2.2lb	1		1	1	1
Tungsten Bucking Bar		1
Microstop Countersink Unit with nylon foot	1	1	1	1	1
#40 Countersink Bit, 3/32"	1	Snap On	1	1	1
#30 Countersink Bit, for 1/8" & #6 Screw	1	Snap On	1	1	1
#8 Countersink Bit, #8 Screw	1	Snap On	1	1	1
#10 Countersink Bit, #10 Screw	1	Snap On		1	1
Left Cut Snips, easy to use offset type	1	Klein	1	1
Right Cut Snips, easy to use offset type	1	Klein	1	1
Straight Cut Snips, easy to use offset type	1	Klein
#40 Aviation Cobalt Drill Bits for 3/32" rivets	1	8	2	1	1
#30 Aviation Cobalt Drill Bits for 1/8" rivets	1	6	2	1	1
#27 Aviation Cobalt Drill Bit		1	1	1
#21 Aviation Cobalt Drill Bit	1	1	1	1	1
#19 Aviation Cobalt Drill Bit	1	1	1	1	1
#12 Aviation Cobalt Drill Bit	1	1	1	1	1
1/4" Aviation Cobalt Drill Bit		1	1	1
12" Aviation Extra Long #40 Drill Bit	1	1	1	1	1
12" Aviation Extra Long #30 Drill Bit	1	1	1	1	1
Deburr Tool, Speed Handle Type	1	USA	1	1	1
Cleco Pliers	1	1	1	1
Cleco Clamps, 1/2" Jaws	4	4 Zephyr	10	4	1
Cleco Clamps, 1" Jaws	4	4 Zephyr	10	4	1
Pop Rivet Tool, with Swivel Head	1	1	1	1
#2 Screwdriver Bits	2
3/32" Universal Cupped Squeezer Set		Snap On
1/8" Universal Cupped Squeezer Set	1	Snap On		1	1
5/32" Universal Cupped Squeezer Set		Snap On
3/16" Universal Cupped Squeezer Set	1	Snap On			1
Flat Squeezer Set 1/8"	2	Snap On	1	1	2
Flat Squeezer Set 1/4"		Snap On	1	1
Flat Squeezer Set 3/8"	1	Snap On		1	1
Vise Grip Dimpler			1
3/32" Rivet Dimple Die	1	Springback	1	1	1
1/8" Rivet Dimple Die	1	Springback	1	1	1
5/32" Dimple Die		1
3/16" - #10 Screw Dimple Die		1
#8 Screw Dimple Die	1	1	1	1	1
#6 Screw Dimple Die		1	1	1
Squeezer Set Organizer		1	1
Squeezer Set Adjustment Washers		1
Stainless Steel Rule, 12"		1	1
Stainless Steel Rule, 24"	1			1
Unibit 1/4" - 3/4" by 1/16ths,	1	1	1	1
Permanent Markers, Sharpie	3	3	1	3
3M Cut & Polish Wheel 6"	1	1		1	1
1/2 x 1 Reducers for 3M Wheel		1
Cleco Fasteners, 3/32"	325	500	325	300	325
Cleco Fasteners, 1/8"	175	300	175	150	175
Cleco Fasteners, 5/32"		10	10
Cleco Fasteners, 3/16"		10	10	10
Edge Deburring Tool, Hex Swivel type	1	1	1		1
Fluting Pliers, Smooth Flute Nylon Jaws	1	1	1	1	1
Fluting Pliers, Deep V with Nylon Jaws	1	1
Rivet Cutter	1	1
Air Tool Oil (excluded on air shipments)	1	1	1
File Card / Brush	1
10" Vixen File	1		1	1
Drill Stop Set of 4 with Allen Wrench	1	1	1	1
Angle Drill Attachment	1		1
Rivet Tape	1		1	1	1
Rivet Set DOTS, Easier than Rivet Tape		1
3/32" Pop Rivet Dimple Die, Springback		Springback	1		1
1/8" Pop Rivet Dimple Die, Springback		Springback			1
Hand Seamer		Klein	1	1	1
3/32" Drive Pin Punch		Klein	1	1
1/8" Drive Pin Punch		Klein	1	1
Scotch Brite Hand Pads		4	1	1
Rivet Length Gauge		1	1
Rivet Shop Head Gauge		1	1	1	1
Technical Resource Manual		1	1	1
Cordless Screwdriver	1
12oz Dead Blow Hammer	1		1		1
Edge Rolling Tool			1	1
Hex Deburr Tool				1	1
#30 Straight Flute Reamer				1	1
#40 Straight Flute Reamer				1	1