Skin Drilling
October 6, 2010 – I drilled the right wing upper skins and clecoed the lower skins in place. Doesn’t sound like a lot, but it’s a lot of holes to drill and clecoes to move.
Total Time: 1:40
Category: Wings
Began drilling skins
October 5, 2010 – OCTOBER!!! I love this time of year!
After a week of class at work, a trip to LOE Saturday, and a triple shift at work, I was able to get things going again and set up to start drilling wing skins.
In what little spare time I had over the last couple of weeks, I made a simple jack to support the middle of the wing on the stand.
When the spars and ribs are on the stand, they sag in the middle, so you need to support the assembly to get the lines straight so you can attach the wing skins for drilling.
I used a 3/8×16 threaded rod, some washers and nuts, and some scrap pieces of wood I had lying around. The nut assembly in the middle is to fix a brain-fart I had when I thought it be brilliant to cut the threaded rod in half. The hole in the bottom piece of wood is 3/8″, and the nut on the bottom is just turned to adjust the height of the jack.
I strung some fishing line between clecoes on each end of the row of fastener holes in the main and aft spars. These pictures show the fishing line, which is straight, not lining up with the rivet holes.
After supporting the center of the spar and ribs, the rivet holes aligned nicely with the fishing line.
I then drilled the doublers for the wing walk. To get in and out of the airplane, you have to step onto the wing. Because the skin is so thin, you install doublers at the wing walk location. This will strengthen that area where you can walk.
The doublers are match-drilled to the existing holes in the inboard wing skin. The inboard edge lines up, and the forward end of the doubler has to be 9/16″ from the forward edge of the skin.
Here’s how the doubler lines up under the skin. You’re looking at the side of the skin that will be inside the wing.
I clecoed the top skins and the doubler to the right wing structure on the stand. It’s always more fun when things start to look aircraft-y.
Here’s what it looks like from the other (bottom) side.
Next, I’ll have to drill all those holes, then do the same with the bottom skins on the other side.
Total Time: 3:05
Drilled ribs
September 22, 2010 – I drilled the ribs through the main and rear spars. The holes in the ribs are pre-punched, but you do have to take them to the final rivet size.
The inboard ribs, which provide support for the wingwalk, are pre-punched, but you do have to add holes. The original holes where the rib attaches to the rear spar will remain open in the final assembly. I almost messed this up. I was originally going to drill the holes from the ribs into the spar, but the instructions say to pick up the holes from the spar into the ribs. Good thing I couldn’t get the drill to go straight…
Anyway, the holes that are “X”d in this picture are the holes that will be unfilled when the wing is assembled.
While the ribs were in position, I wanted to figure out where the holes for the conduit would be located. I opted for the location called for by Vans.
The hole is 3/4″ and is located below and aft of the forward lightening hole in the ribs. After trying to visualize how to make sure I got the holes in the same place and the same orientation in every rib per wing, and much discussion with a friend, I decided to make a template out of a pizza box. (Thanks Grimaldi’s!) The template fits one way within each rib, and the ribs are mirror-image between the left- and right-hand orientations. I back-drilled from the rib into the template, then used the template to drill one of each part number of rib; the W710L, W711L, and W712L.
Then I flipped and clecoed a -R rib to the appropriate -L rib, and back-drilled that rib. I didn’t want to use the cardboard template for each rib, because eventually the hole would get wallered out. (Wallered—that’s a technical term)
Once the ribs were all piloted, I used my handy Unibit to take the holes all to 3/4″. The red line is drawn at the next size above 3/4″, so I knew to stop when I reached that point.
Now when I get the holes drilled for the right wing ribs, I can deburr them all at once and get ready to paint.
I moved the left wing main spar off the stand, and placed the right spar there, then attached the ribs and the rear spar.
I did have another senior moment doing this as well. The plans show you the left wing, and you have to make sure that you place the correct part number rib in the correct location, with the flanges pointing in the correct direction. I saw nothing about any difference between the left and right wing, so when I started to put ribs in place on the right wing, I ended up with 2 ribs that were incorrect. After a quick call to Van’s, where they NEVER make you feel stupid, I learned that a -R rib in the left wing is matched to a -L rib in the right wing, and so on.
The right wing is now clecoed together, and I made my quick Sharpie marks where the conduit holes will go.
Total Time: 3:15
Rear Spar and ribs, continued
September 10, 2010 – Nice day today. I assembled the rear spars and did the preliminary fit of the left wing ribs and spars on the stand.
These three pictures show the three areas of the rear spar with the doublers attached. The open holes are where other parts will attach later.
I then clecoed the main ribs to the fwd spar and then clecoed the aft spar in place.
Here’s the left wing as it sits right now.
Total Time: 2:25
Rear Spar and ribs
September 9, 2010 – I’ve continued the rear spar parts by cleaning, alodining and priming them. Today was sunny, but a bit humid after our storms. I got them primed anyway.
I also got the ribs straightened and fluted. I thought that pile would not disappear, and I got a blister for my trouble. I did all but the tank ribs. My concentration coming up will be to get the ribs ready for paint. Since I will not paint the tank parts, they can be fluted later on.
Total Time: 5:25
Rear spar work
September 6, 2010 – A few days ago I started the doublers for the rear spar.
I located and drilled the center and outboard doublers that attach to the rear spar. These doublers reinforce the mounting of the aileron hinges. The center doubler has a hole that the control rod for the aileron passes through. That hole had to be transferred to the rear spar. I clamped and clecoed the doubler in place, traced the outline of the hole, and began by drilling starter holes with a unibit. I then used a rotary file in a die grinder, and finished up with a sanding drum on my Dremel.
I then located and drilled the holes for the doublers at the inboard end. Next part is deburring, cleaning and priming. I don’t think the weather will cooperate for the next few days. though.
After deburring the ribs, I’ll need to eventually get set up to drill them to the spars. So I decided to set up my wing stand. I got the stand from Kenny Haberstroh in Justin, and I had to figure out how he had set it up. After a phone call and some e-mailed pictures (Thanks, Kenny!), I got it set up.
Total Time: 3:10
Wing Ribs deburred
September 6, 2010 – I had some down time at work for the last couple of days, so I brought in all the wing ribs and got them deburred. Better there than to listen to my compressor run nonstop at home…
I just got rid of the rough edges from forming. I’ll need to go back and do a final polish after drilling and dimpling, prior to paint.
Total Time: 2:50
Installed tiedowns; Main Spar prep complete
September 1, 2010 – The tiedown brackets are installed.
I tapped the tiedown brackets per the drawings: 3/8″ x 16, 1″ deep. These holes will accept the tiedown rings that will secure the airplane in the event of high winds while parked.
I then drilled and installed the nutplates in the spacers and the tiedowns, then cleaned, primed, painted and installed.
On the aft side of the spar, using the nutplates installed in the tiedowns, are the brackets for the aileron bellcrank assembly.
I’ve set the main spars aside, and started on the aft spars. Doublers for the inboard ends of the aft spars get trimmed on the RV-7. Since the trim is the same on 4 pieces, I trimmed one per the drawing, then clecoed the 4 pieces together and trimmed the rest so they all match.
Total Time: 4:35
Drilled tiedowns
August 29, 2010 – Today I decided to visit the therapist in the garage and drill the tiedown brackets.
The first thing you do is make lightening (reduce weight) holes in four spacers. I cut the material per the plans and used a spot-facer to make the center holes. The plans call for a 1″ hole. I didn’t have the means to make 1″ holes, so I made them 13/16″. I don’t think there’s a lot of edge distance for a 1″ hole. especially since you have to drill additional holes for nutplates.
The next step is to drill one hole in the tiedown bracket material at a specific location called for in the plans. You then bolt it to the spar and back-drill the remaining holes. I also drew lines along the backside of the brackets so I could make sure that it lined up when in place on the spar. Just look through the holes in the spar, and if you see the lines, you’re reasonably sure that the bracket is straight.
I then placed the spacers on the spar using carpet tape to hold them in place for drilling. The square is to ensure that they are even with the end of the spar doubler.
When everything is in place, you just drill through the existing holes in the spar to the brackets and the spacers.
Total Time: 1:40
Spar nutplates complete
August 26, 2010 – It’s been a while since I’ve been able to do a good day’s work, so I got it out of my system.
Countersinking the holes for the tank attach nutplates was a bit intimidating, and I had a rough hole or two to get started, but once I got into it, the job kinda flowed on. After figuring out the settings for the countersinks, I drilled a plate with some holes to accept the pilot of the countersink to prevent chatter, then I drilled away.
Everything looks pretty good.
I then installed the nutplates for the tanks and for the access panels on the bottom of the wings, and the 1/4″ nutplates for the center section.
Total Time: 5:20
Set up and ready to start…
August 24, 2010 – Well, we’re on the cusp of a break in the heat. Yesterday it was 107. Today a “cold” front is moving through, and tomorrow it will only be 90. It’s amazing how much we appreciate the small things when they’re not here.
Anyway, I finally got everything more or less in place, and I started on the spars. VERY intimidating because I don’t want to even know what one of these would cost to replace if I make a mistake. No wonder they’re anodized gold…
I started by labeling the spars as to which end is up, then I secured them in place on the table and began countersinking for the nutplates. I only got one side done on each spar. I guess I’m going to go with Van’s method for countersinking the screw holes that accept the dimples in the skin material. I’ll do that tomorrow when it’s cooler…
Total Time: 1:15
Wings Delivered!
August 18, 2010 – The wings were delivered by ABF promptly. The driver pretty much took charge of the unload, and everything appears to be OK.
…And the obligatory pictures of how well Van’s packs everything, and the resulting pile o’ paper…
Wings!
August 17, 2010 – I just paid for shipping, and the wings will be delivered by ABF tomorrow! I called Van’s during shipping week, and they said the wings were in crating, and I’d hear next from the shipper (ABF). I got a final invoice from Van’s with the Bill of Lading on Saturday, with a tracking number. Crates arrived in Dallas yesterday, so I called this morning to arrange a time. Set up for tomorrow, and paid my bill right then and there. Shipping was $298.40…honestly about $100 less than I anticipated.
Pictures tomorrow!!!
Wing stand
June 9, 2010 – No pictures, but I went up to Propwash in Justin to pick up a wing stand and cradles from another ex-Deltoid, Kenny Haberstroh. Better to recycle than to build a new set, and he needed to clean out the hangar anyway. Kenny’s RV-7A is flying. We also went to visit Bob Malechek and his RV-7A. Always good to be inspired. Thanks, Kenny, and thanks to Mike Dillon for helping with transportation!
Wings Ordered
May 28, 2010 – I ordered my wings today. Right now I expect delivery in mid-August. I’ll keep you posted.