Interior Panels

10-Oct-2022 13:16 ⋅ Leave a Comment ⋅

Now that the airplane has been moved to the airport and wings attached, final painting and installations can proceed.

Interior panels from Aerosport Products were primed with PPG DP48LF white primer.  Later the panels were painted PPG Concept Boeing Grey.

 

 

 

The foam backed, fabric material was glued into place on the Aerosport headliner with contact cement by professional auto specialists. (Don’t ask why I did not do this myself). The backing fiberglass was then fitted with Velcro strips and attached to corresponding strips on the canopy.

 

 

More views of the overhead console and installed headliner..

 

 

 

 

The left photo shows fitting the map pockets on the forward interior panels prior to prime/paint.  The right photo shows the baggage bulkhead after painting.

 

 

 

A Blue Seas power outlet was fitted onto the baggage bulkhead.  A 10A fuse and toggle switch for directing trickle charge power to either PRI or SEC battery were installed with switch guards.  This outlet is not intended for ever jump starting the aircraft.  The required EXPERIMENTAL decal was installed on the upper bulkhead cover.

 

The lower bulkhead cover was fitted with UHDP wear blocks for the rear shoulder harness cables.  The right picture shows a rear interior panel with the air vent cover installed.

 

 

Preparation of the Aerosport dashboard cover included installation of covers for the panel fan outlets and trimming the edges for fit.  After trim, I used my fledgling sewing skills to dress the edges against fraying.

 

 

The center console and control stick wiring was completed and tested.  Labelling of the jack ports was with a Brother P-touch. I would have preferred a laser etched alternative, but maybe than can be a future project.

 

 

 

The dashboard cover was secured with 1″ and 2″ Velcro strips.

 

 

 

 

Final dashboard cover, center console and control sticks installed…

 

 

 

 

Front and rear footwell carpet…

 

 

 

 

Rear seat and baggage compartment carpet…

Posted in: Custom Elements, Interior, Prime/Paint, RV-10 Build Project

Wing Attachment (3) and Misc

03-Oct-2022 13:10 ⋅ Leave a Comment ⋅

Finish configuration of wing root covers required installation of a few system components.

The rear spar bolt was an AN6-11, anchor nut and cotter pin. The wing root fairing supports are held primarily by LP4-3 pull rivets.

 

 

 

A custom fuel line, filter and shut-off valve from TSFlightline was installed.  This configuration should allow the filter to be removed for annual inspection without the need to completely drain the tanks.

 

 

The massive and high precision bolts (NAS1309-58 and NAS1306-58) were tightened with the nylon insert (AN365-918 and AN365-624) lock nuts and regular/thin washers to expose sufficient bolt threads.  The torques were 100 lb-ft and 20 lb-ft respectively

 

 

The Stewart-Warner IE-F-385C (right) fuel sender was attached with NAS180-2-0808 (8-32) hex head bolts and Permatex Aviation Forma-Gasket sealer compound.

 

 

Fuel sumping valves were installed and fuel vent lines were fabricated from 1/4″ stainless tube.

 

 

 

Lastly a Garmin GTP59 air temperature probe was installed near the first inspection port.  This last run allowed the wire bundles to be consolidated and attached via CPC-24 connector to the fuselage.

Posted in: RV-10 Build Project, Section 44, Wing Attachment

Wing Attachment (2)

21-Sep-2022 15:54 ⋅ Leave a Comment ⋅

The same day as ‘the big move’, we attached the wings with provisional fasteners, then began work fitting the wing root fairings.

Following the Van’s instructions, the wings were first pinned into place with drift pins and hardware store 3/8″ bolts. These bolts have much looser tolerances (~.010 “) as compared to the high precision NAS1309-58 and NAS1306-58 bolts called for final insertions (done at a later date).

 

 

Both wings were provisionally attached with just a few main bolts. Thanks to Eric, Peter and Aaron for help during the wing transport and attachment activities.

 

 

 

The wing root fairings were trimmed to match the contour of the fuselage. This left about a 3/16″ gap between the fairing and fuselage. This gap will be filled with black rubber edge molding as some vibration and flexing of the wing will be expected during flight.  On the right stiffeners, upon which people will stand when entering the cabin, are clecoed then riveted onto the upper fairing panels.

 

The inner sides of the fairings were scuffed, washed and then sprayed with SEM Self-etching primer (grey 39683). The outer sides were scuffed, treated with Prekote, then primed with DesoPrime followed by application of Snow White Desothane CA8800 paint. Wheel pants and fairings were painted at the same time.

Posted in: Prime/Paint, RV-10 Build Project, Section 44, Wing Attachment

Logistics (Fuselage and Wing Moves)

21-Sep-2022 15:46 ⋅ Leave a Comment ⋅

The 2022 Labor Day weekend saw the transportation of fuselage and wings to the final assembly location in my hangar at KTTA.  Many thanks to Terry G. for the use of his equipment, his expertise and patience in dealing with a very nervous builder (me) during the “Big Move”.

The cowl was attached to the fuselage for transport, then pushed outside the shop to be loaded onto a 22′ heavy equipment trailer. Initially we intended to load the plane facing forward, but found rolling it on backwards would be much easier.

 

 

 

The trailer was about 8’6″ wide, but the main landing gear wheels were about 8′ even.  As a result, the movable ramps had to be relocated outwards to accommodate loading the plane. An electrical winch attached to the tail cone started pulling the fuselage up the ramp.  Eventually the pull angles were wrong, so we used the body weight of two people to hold down the tail while others pushed the main wheels between grates on the loading ramp.

 

 

Loading was a very slow, deliberate process as the leeway between main wheels and edge of the trailer was only about 3″ on either side. The fuselage was carefully inched backwards up the ramp and into position.  A wheel coming off the trailer would have spelled disaster and could have ruined the entire fuselage.

 

 

More photos inching the fuselage onto the trailer.

 

 

 

 

Eventually the main wheels were chocked close to each edge.  Multiple ratchet straps held down the main and front wheels. These were tightened into a very stable configuration; one secured from movement in all directions (left, right, forward, backwards, and up).

 

 

Rolling down the highway towards the airport!  The actual road transport went without any issues with a safe arrival at the end.

 

 

 

Multiple volunteers helped unload the fuselage – basically the reverse of the load process, but much easier with the gravity assist.  Here the fuselage was moved off the trailer…

 

 

 

… and into the hangar.

 

 

 

 

Now that the ‘big move” was complete, the protective film on the windows was removed.

 

 

 

 

WING TRANSPORT

The wings were moved to the airport with Tal’s trailer just as previously posted from house to shop.

 

Posted in: Logistics, RV-10 Build Project

Wing Attachment (1) (Paint)

21-Sep-2022 15:34 ⋅ Leave a Comment ⋅

Painting the wings required about three weeks of preparation, surface treatment, and priming prior to paint application.

Custom wing rotisseries were created by Terry G. specifically for RV wings.  I created some special attach plates to directly accommodate the RV10 wing bolt patterns. Here the wings are mounted, scuffed with maroon Scotchbrite pads, and treated with Prekote before priming with DesoPrime Grey.

 

 

Prior to scuffing the wings I fitted the outboard side of the wing root fairings, but made a mistake by dimpling one of the nutplate holes in the wrong location. The nutplate still went on fine, but did not align perfectly with the pre-drilled holes in the Vans cover piece.  In the long term this is not a big issue, especially since this area will be covered by wing walk material anyway.  However, it was aggravating not to have paid close enough attention to the plans.

 

Fastener holes for the flaps and ailerons are filled with ear plugs or electrical tape to prevent covering with primer or paint.

 

 

 

After initial prime and paint a few runs and poor coverage were discovered.  As a result the wings were wet sanded with 600 grit, then repainted.  The final results were very good.

 

 

 

Here the wings were ready for the move to the airport.  They had been painted 2 weeks before and were allowed to cure completely before being taken on the highway.

 

 

 

HS RESPRAY

The original quality of the HS tip bulkhead paint did not meet expectations.  So while there was extra paint available from repeat covering the wings, I decided to redo the ends.  Here the ends are shown sanded and ready for another coat of primer and paint.

Posted in: Logistics, Prime/Paint, RV-10 Build Project, Section 44, Wing Attachment

Firewall Forward (1)

21-Sep-2022 11:21 ⋅ Leave a Comment ⋅

A variety of firewall forward components were added between paint preparation stages.

Here the standard oil plug was replaced with a quick-change unit.  Note the new unit is secured with .032 Safe-T wire tool.

 

 

 

Next the throttle and mixture levers were adjusted and tightened to final configuration. Castle nuts secure the levers and jam nuts immobilize the push-pull cables.

 

 

 

The sensor manifold contains units for oil (150psi), fuel (75psi) and MAP pressure (30psi).  All sensors were sealed with fuel resistant lubricant and torqued to appropriate tightness.  The manifold block was then fastened to the firewall through pre-installed (QB kit) AN3 nutplates.

 

 

The oil cooler unit was installed and feed lines attached from the engine block.  The right photo shows the manifold pressure line teed for a line to the Surefly magneto, which has the ability to adjust ignition timing based on MAP pressures.

 

 

 

A further complaint from many builders is oil leaking from the standard tube/hose/clamp configuration on Lycoming engines from cylinder heads to oil sump. I obtained the flexible SS hose kit from TSflightlines, then added fire sleeve myself prior to installation.  Two notes – the fire sleeve was probably not necessary (overkill on my part), and access to the oil sump fittings was much easier without the exhaust headers being installed.

 

 

This shows a provisional install of the primary alternator drive belt (Gates XL 7360). Final tightening of the belt and torquing the retainer bolts will occur once the propeller has been mounted.

 

 

 

The right photo shows the open ports for CHT probes in the cylinder head, plus the .032″ safety wire approach used to hold the forward cylinder baffle flange. The other photo shows the CHT probe installed with 30 lb-in torque (as per manufacturer instructions). The probes still need to be attached to the GEA24 engine monitoring system.

 

 

Exhaust headers and exhaust pipes with heat muffs were installed. Then 2″ SCAT tubes were connected between the engine baffles and the exhaust muffs.  Finally additional SCAT tubing was run to the heater vent distribution box.

 

 

The exhaust pipes have a flexible ball connection with the rigid exhaust headers. An isolation kit resides between the engine mount and exhaust stack to correctly position the output orientation. It also serves to keep high temperatures off the engine mount.  About 1/2″ – 3/4″ separation was achieved between the exhaust pipes and the lower cowl sections. Later the cowls will be covered with a thin ceramic blanket and reflective aluminum shielding to keep engine heat from discoloring the cowl paint.

Posted in: RV-10 Build Project, Section FF1 - Engine Installation, Section FF4 - Fuel System, Section FF5 - Oil System, Section FF6 - Exhaust System

Gear Leg and Wheel Fairings (2)

21-Sep-2022 10:40 ⋅ Leave a Comment ⋅

The last few months have been focused on completing any prime/paint activities, as the paint booth facilities will not be available to me after October 31

The front wheel fairing needed some AwlGrip filler to even the transition from fore to aft section. The final painted assembly looks very good.

 

 

 

The right photo shows the initial shaping of the leg fairing. A construction laser was then used to locate the nutplate holes through the fiberglass web for accurate drilling.

 

 

 

Then .063 Piano Hinge was attached and a pin fabricated to length.  The final configuration is shown on the right.  Subsequent steps related to smoothing the rivet lines (namely resin fill, followed by SuperFil, Smooth Prime, spot putty, prime and then paint.)

 

 

The steps were powdered coated and painted in previous posts.  Here the tread portion was treated with UltraWing Walk anti-slip compound.  This material contains heavy duty grit particles and cured to a rock hard surface.  This will provide an excellent surface on the installed steps for getting into the airplane.

 

 

The steps then served as a reference point for leveling the fuselage and horizontal alignment with the ground to set the appropriate angle on the main gear fairings.  Again construction lasers were used for accuracy.  The left photo aligns the step reference parallel to the fuselage centerline, while the right ensure vertical alignment to a plumb bob hung from the step.

 

 

With references now vertical and horizontally aligned with the fuselage, the fairing back-sweep angle was set to direct point backwards to the step reference point.  This should ensure minimized wind resistance during flight.

 

 

 

After setting the proper sweep angle on the leg pieces, the intersection fairings were drilled to the same orientation. Eventually these parts will be secured with nutplates and will constrain the leg fairly in the correct configuration.

 

 

 

Here were two views of the final setups.

 

 

 

 

After completing the fairing alignments, I decided to complete blending the intersections to the wheel fairings. I had originally thought to do this after the flight testing phase, but moved forward with the repainting due to the paint booth access limitations.

Posted in: RV-10 Build Project, Section 30, Step Installation, Section 48, Gear Leg and Wheel Fairings

Gear Leg and Wheel Fairings (1)

20-Jun-2022 15:44 ⋅ Leave a Comment ⋅

Aligning and fitting the wheel pants required use of two lasers, one for the aircraft centerline and one for accurately locating the pant retention bracket holes.

The fuselage had to be leveled, then raised so wheel installation would leave the wheels just touching the ground. Here the wheel dollies from Charlie Derk (with many thanks) were removed for actual wheel installation.

 

 

 

 

The main wheels and brake fixtures were bolted into place. Again the plane was leveled and wheels just barely touching the ground.

 

 

 

A .75″ x 1.0″ spacer block established the upper position of the main wheel pant. With the forward and aft sections clecoed together, alignment to aircraft center and level reference datum could proceed.

 

 

 

A regular construction laser provided an accurate centerline for the airplace. Measuring offsets to this reference line and the front/aft of each wheel pant ensured parallel alignment. The pants were also measured from the floor to their own centerlines to make sure they were parallel with the ground.

 

 

 

A second construction laser provided accurate location of the holes drilled in the retention brackets. The same processes described above were used with both main pants and the forward wheel pant.

 

 

 

The forward wheel was first installed, then the side breakout pull of ~25lbs was measured with a baggage scale. The Nose Fork Assembly nut was tightened to approximately achieve this value.  I have heard from other builders that this nut will need adjustment many times during the fly-in period.

 

 

All wheel pants drilled and temporarily clecoed in position in the left photo.  Forward wheel pant protectors were then aligned and holes drilled to prevent two bar damage.

 

 

 

Finally for this section, the pant retention brackets were surrounded with resin/silica to provide larger bearing surfaces during normal flight operations between the fiberglass and the brackets.  Additional resin will be applied in a later post to round over and slightly enlarge the bearing points.

 

 

MISCELLANEOUS

The door windows were retaped prior to the next batch of final paint.

 

 

 

 

The inital painting of the horizontal stabilizer left a few runs and some flaking along the trailing edge of the upper side.  Resanding and air brush priming were performed before another (hopefully final) paint coat was applied.

 

 

 

 

The #2 cylinder fuel injector line required two adel clamp locations to secure between the prop governor cable bracket.

Posted in: RV-10 Build Project, Section 46, Engine Mount and Landing Gear, Section 48, Gear Leg and Wheel Fairings