David's RV-10 Build

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Re: David's RV-10 Build

Unread post by ace-jack » Tue Jun 04, 2013 8:24 am

Thanks Chalkie

I made it fit :)

Update:
Total time: 27.25hrs

Over the weekend I dimpled and countersunk the VS parts to a point where I now need to prime parts for assembly. On Sunday, it was quite windy and I decided not to risk getting dust and goggas mixed up with the primer by painting and therefore I decided to start working on the rudder.
Rudder Components.jpg
Rudder components assembled.jpg
Rudder Skin attached on one side.jpg
I found it quite difficult to debur the rudder skin due to its flexibility and size. Cleco'ing it to the skeleton gives it a lot more rigidity and one can debur more effectively. I will do the same with the other rudder skin.
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Jan
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Re: David's RV-10 Build

Unread post by Jan » Tue Jun 11, 2013 6:59 am

David - this is a biggie you have taken on. Well done so far.

On your DRDT table - move your table ( the part with the carpet on ) further back until the front edge is flush with the front of it. Then move your DRDT as far forward as possible. Also turn around your dimpe die so that the male part is on top.

This way you can easily reach into the bent skins. You just let the one half hang down in front while dimpling the other half. Having the male die on top also stops you from scratching the skin as you move from hole to hole.

I am deep into an RV10 now and you are welcome to come and visit me at The Coves to see the project.
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Re: David's RV-10 Build

Unread post by ace-jack » Tue Jun 18, 2013 8:33 am

Thanks for the insightful toolbox talk yesterday. RVI is truly an inspiration. =D>

Update:

40.75hrs

Last week I prepped the VS and Rudder parts for priming.

I did not get much done over the last weekend as we flew to Alldays on Friday. It was my first long distance flight with the family and all went well. For fathers day, I took my father, brother and nephew for a sunrise flip over one of the farms in the area. We flew back on Sunday dodging some clouds via Polokwane as Alldays had run out of fuel!

Yesterday, the misses and I went to visit Jan at his home at the Coves.

After returning home with some priming knowledge gained, I primed all the parts for the VS and the Rudder.

So, this week is the week where the building actually begins! Wish me luck! 8-[
Rudder and VS parts primed.jpg
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Re: David's RV-10 Build

Unread post by ace-jack » Mon Jun 24, 2013 8:46 am

Update:

55.5hrs to date

Last week I started riveting the VS spar and started to attach the skin of the VS to the skeleton. It takes some process management to figure out in what sequence you need to rivet in order to keep one side of the skin open for inspection! I also back riveted the rudder stiffeners to the skins and - I have however run into a snag - I need tank sealer for the rudder trailing edge! :? #-o Does anybody have some spare which I can buy off them or is there a local alternative that I can use?
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Jan
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Re: David's RV-10 Build

Unread post by Jan » Mon Jun 24, 2013 10:07 am

Try Placo or RAP at Wonderboom.
Or
Placo or Comair at Lanseria.

Rivet on both skins and leave open the leading edge - your AP will surely be able to see in there.
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Re: David's RV-10 Build

Unread post by Goose1 » Mon Jun 24, 2013 8:44 pm

ace-jack wrote: I need tank sealer for the rudder trailing edge!
Jan wrote:Try Placo or RAP at Wonderboom.
Or
Placo or Comair at Lanseria.
Get it from NAC at lanseria they are the cheapest R462.00 for a 1kg, placo same prize for 1/2 kg

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Re: David's RV-10 Build

Unread post by ace-jack » Mon Jun 24, 2013 9:05 pm

Thanks guys

Placo and RAP don't have stock and NAC didn't answer the phone earlier. Will try again tomorrow
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Re: David's RV-10 Build

Unread post by Chalkie » Tue Jun 25, 2013 6:58 pm

Don't use fuel tank sealant (ProSeal) as it is too flexible and the (trailing edge) skins will bulge between rivets if the sealant is applied too thick.

Go to AMT and buy 2 part structural adhesive, and glue the bits together properly.

I will post a picture of the glue and part numbers later. :)
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Re: David's RV-10 Build

Unread post by Chalkie » Tue Jun 25, 2013 8:26 pm

Here is a picture of the adhesive to use...
AMT Adhesive.jpg
Looking at your priming, it is evident that you have not scuffed the metal at all. This is evident by the red part number paint still being visible under the paint. Chances are good, that this primer will come off the metal. You need to scuff the metal (wet sanding) with Scotchbrite or abrasive paper to give the paint a chance to adhere. Aluminium is an oily metal...

Clean the red dye/paint off the metal before you paint, because it will bleed through layers of subsequent colour you might apply. (If this were the outer side of the sheet metal.)

Remenber; the idea of building an aircraft: is education. :)
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Re: David's RV-10 Build

Unread post by ace-jack » Thu Jun 27, 2013 8:14 am

Hi Chalkie,

Thanks for the heads up and the priming lesson.

With regards to the scuffing, I did use a electrical orbital sander with a scotchbrite pad to roughen up the material on the sheet metal and by hand on the smaller components.Obviously not enough. I believe that the primer has bonded to the metal sufficiently to put my head on a block to say that should it come off, I will eat my VS. 8-[

I will get in contact with AMT today.
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Re: David's RV-10 Build

Unread post by Chalkie » Sat Jun 29, 2013 8:28 am

I am not too sure about the 'electrical orbital sander' that you used. I have visions of mangled metal and water + metal + electricity sounds like a recipe for disaster.

Scotchbrite by hand, use lots of water; add one teaspoon full of sugar soap to a bucket of water when sanding, rinse thoroughly with clean water and allow part to dry in the sun before painting.
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Re: David's RV-10 Build

Unread post by Rob K » Mon Aug 19, 2013 11:55 am

Hi Dave,

Just read through your thread so far.

Great going, I have huge respect for anybody who takes on a project of this magnitude.

To Chalkie and Jan, amongst others - you guys make flying RVs in SA the fantastic experience it is and you make us proud to belong to this incredible group.

Kudos to you both.

Regards,

Rob
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Re: David's RV-10 Build

Unread post by ace-jack » Mon Aug 19, 2013 12:37 pm

Hi Rob

Thanks - it has been a HUGE learning experience but I have been enjoying every minute of it.

Hour update: now on 107.75 hrs.

Completed the VS and the Rudder after my AP inspection last week.
Centurion-20130816-00299.jpg
Centurion-20130817-00300.jpg
Centurion-20130817-00301.jpg
Centurion-20130817-00302.jpg
Centurion-20130819-00322.jpg
On the HS: I have primed the spars, deburred the inspar ribs, deburred and dimpled the HS skins.
HS Spars Fitted.jpg
Centurion-20130819-00321.jpg
We might be going away this weekend and therefore I will probably only get to prime all of the HS parts next weekend.
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Re: David's RV-10 Build

Unread post by ace-jack » Sun Sep 22, 2013 10:16 am

Update

TT: 147.75

The horizontal stabilizer has been completed last week. Apart from the VAST amount of rivets that needed to be set, the experience was quite satisfying to complete a part of that size. I am very happy with the outcome.

I have started with the elevators. It is frustrating to say the least to cut the ribs in half, only to put them together again in almost the same position?

I have bent the tabs on the elevator skins and assembled the bottom half.

Still having fun :)
HS Complete.jpg
Elevator assy.jpg
Elevator assy 2.jpg
Elevator skins fitted.jpg
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Re: David's RV-10 Build

Unread post by BlueHawk » Tue Jan 28, 2014 6:13 pm

Hi, whats happening with your build?
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