Monthly Archives: July 2018

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Engine, Propeller (Airventure 2018)

29-Jul-2018 11:08 ⋅ Leave a Comment ⋅

Eric and I drove to Airventure 2018 in Oshkosh primarily to order an engine and propeller from Van’s.

The show discounts from Van’s amounted to $1000 when ordering both components together, plus free shipping.  The engine is a 260hp Lycoming XIO-540-D4A5, while the propeller is a 3-blade Hartzell C3Y1R-1N/N7605C with a C-4582-P spinner (picture at left).  The engine will be added to the production schedule and should be built in 3-4 months.  The propeller is expected to ship in 4-6 weeks.  After much discussion, I was also able to get a free hat from Lycoming.

 

 

We stopped by SteinAir to ask a few questions about G5 autopilot connections, and VOILA! – they had a demonstration panel with nearly the exact equipment and layout I have been imagining for some time.  This is essentially how mine will be configured with a few alterations for internal lights, USB power and CO2 sensors.  Otherwise excellent.

 

 

These two products were obtained during the week. Both are very versatile for aeronautical and home use.  My first application was replace an air hose clamp with .032 safety wire. The combination works great and eliminates the sharp edges of the hose clamp when handling.

 

Posted in: Logistics, RV-10 Build Project

Empennage Attach (5)

29-Jul-2018 10:46 ⋅ Leave a Comment ⋅

Upon return from AirVenture 2018, I began assembling parts for the trim mount bracket.  These parts were alodined in an earlier batch, but needed to be primed before riveting.

The pushrod ends and small parts for the trim mount bracket were primed using PPG DP40LF with an old airbrush I had acquired almost 40 years ago.  The amount of paint applied is very easy to control and the very low volume in the paint bottle was perfect for this small batch. The idea is prime just those parts touching one another with the airbrush, rivet, then prime the larger external surfaces of the whole assembly with the regular spray gun.

 

 

The trim mount parts were clecoed together prior to rivet assembly.  A pneumatic squeezer with a longeron yoke was needed due to geometry requirements to reach the Trim Cable Anchor Brackets.

 

 

 

Here are the riveted Trim Mount Bracket Assembly and the Trim Servo Links. The next actions were to continue work on the secondary battery mounting platform, battery contactor mount brackets, and the ELT device mount.

 

Posted in: RV-10 Build Project, Section 11, Empennage Attach

Aileron Torque Tubes (2)

08-Jul-2018 13:41 ⋅ Leave a Comment ⋅

While the title of this post is about torque tubes, the general work this week is alodine and prime various other parts as well.

ALODINE

The process to wash, acid etch, rinse and alodine parts has been covered in previous posts. The difference here is performing the task in the climate controlled splendor of my new basement. Wonderful how not having to sweat at every motion seems to make the work go faster.

 

 

 

This batch included parts from control push rods, end caps, rudder trim mountings, cabin rivet backing plates and more accumulated during various stages of fabrication.  Unfortunately the alodine was at/near the end of its useful life, so only a light coating was achieved.  A new supply has been ordered, so a repeat of the last stage may be needed.

 

 

PRIME

Priming the interiors of the flap pushrods and torque tubes is recommended in the plans.  A small quantity of two part, epoxy primer (PPG DP40LF) was mixed.  A small bit of acetone was added to help the primer flow better along the inner walls of these tubes.

 

 

 

Here the primer is injected in the open end of a flap pushrod.  The rod is then shaken to distribute the primer.  Excess material was poured out – though not much came out.  Most remained well attached inside the tubes.  Now let them dry thoroughly, then assemble as needed.

 

 

 

 

CUSTOM PARTS

New parts outside the plans are laid out for attachment to the center control bellcrank housing.  One is a auxiliary battery platform.  The other is a mounting bracket for two battery contactors.  The original Vans housing is configured for one contactor, I need two for the electrical system on my plane.

 

 

 

 

 

Posted in: RV-10 Build Project, Section 23, Aileron Actuation

Aileron Torque Tubes (1)

01-Jul-2018 11:39 ⋅ Leave a Comment ⋅

The aileron torque tube assemblies were fabricated this week.

The aileron torque tube assemblies consist of a straight steel tube collars between powder coated torque levers  with threaded end caps.  The first step is insert the end caps in the torque levers and drill holes for MSP-42 rivets.  The right picture shows before and after riveting.

 

 

 

The drill press, two precision V-blocks, and clamps are used to secure the cut-to-length steel tubes inserted in the longer torque levers for  accurate alignment.  The desired outcome is fastener bolts perpendicular to each other. Very good result.  (I love that drill press).

 

 

 

Next the distance between the end caps is adjusted to 17 25/32″ overall length. Before drilling through the steel tube, the angle between the levers is clocked to proper alignment.  Here two gauge blocks are stacked to give the 5/16″ distance to make the angle called for in the plans.

 

 

 

The left picture is the drill press setup for the final bolt hole drilling.  The completed torque tubes need to be taken apart for priming inside and out.  This process will be done with a batch of elevator, aileron and flap pushrods.

Posted in: RV-10 Build Project, Section 23, Aileron Actuation