Empennage Attach (5) and Empennage Fairings (7)

25-Jul-2020 12:44 ⋅ Leave a Comment ⋅

Attachment of the horizontal stabilizer enabled the final configuration of the elevator control rods and elevator stops.

Match drilling the forward spar shims and aft bracket were performed to mount the horizontal stabilizer.  The UP position of 30 degrees exactly matches specification. The DOWN angle, even after considerable filing of the stop bracket, was finalized about a degree shy of the expected 25 degrees.

 

 

These pictures show the vertical stabilizer forward and aft attachments after the elevators were removed. Two mounting shims under each forward HS spar attach pad were also match drilled and bolted on before VS install.

 

 

The empennage gap cover under the HS was clecoed into place. The rear section overlaps the inspection port cover.  Both are match drilled together through the longeron.

 

 

 

The plans call for only three screws per side to hold the forward section of the empennage fairing.  Many pilots have suggested additional fasteners to prevent fiberglass bulging due to air stream pressure over the fuselage. Here intermediate points were drilled midway between the default points. Nutplates for #6 screws will later be added to the upper aft skin.

 

 

Front and rear photos of the match drill screw points on the empennage fairing. The aft points require special care when trimming to not interfere with either the elevator horn or the rudder motions.

 

 

With the main empennage components staged in place, the whole fuselage begins to look like an airplane.

 

 

 

 

OCTOBER 2020 UPDATE

Further trimming and edge preparation has been completed on the fiberglass empennage prior to priming.

Edges were measured against a scribe line formed into the part. Enough ‘meat’ needed to remain for the attachment screws to have sufficient structure to hold properly.

 

 

 

Because of the extra holes added, smooth curves based on circular patterns were applied.  Since fiberglass always seems to have numerous pinholes from the manufacturing process, a coat of Smooth Prime helps with initial underlayment.

 

 

 

MISCELLANEOUS

The forward and aft NACA air vents were fastened with ProSeal and #4 stainless screws into position.  Later SuperFil will be applied to smooth out the backing plate rivets.

Posted in: RV-10 Build Project, Section 11, Empennage Attach, Section 12, Empennage Fairings

Flap System

05-Jul-2020 10:32 ⋅ Leave a Comment ⋅

Next section was installing the flap levers and Pittman flap motor from Vans.

The UHMW (ultra high molecular weight) guide bearings must be relieved to fit under the kick plates in the rear footwell.  The various stages of the trimming process are depicted on the left.  The right photo was taken during match drilling AN3 bolt holes in the flap crank and torque tubes.

 

 

Proper alignment of the flap crank with the flap horns was achieved by clamping the center crank to the workbench, then using the W-730 Bellcrank Jig to establish the correct angle on the horn.  Curiously these call for AN4 bolts, while those for the flap crank are specified for AN3.

 

 

Insertion of the torque tubes was supposedly achievable from the inside the footwell, but I found pushing through the exterior access holes to be much easier.  The quick build exterior holes first needed to be relieved slightly to prevent binding on the torque tubes.

 

 

The flap motor comes without an electrical connection. The left picture shows a Molex 18-24AWG connector crimped into place.  The wires near the connector are held together with heat shrink.  The flap crank with UHMW bearing are shown on the right.

 

 

These photos show the final configuration of the flap motor to flap crank, plus a close-up of safety wire around the pivot point.  It was a slow, tricky job to drill a 1/16″ hole in the motor pushrod.  The final attachment of the flap horns will be performed after the wing root area is primed and painted.

 

 

A custom flap position sensor mount is fabricated for a Ray Allen POS-12  device.  More on this later…

Posted in: RV-10 Build Project, Section 40, Flap System

Control System (1)

05-Jul-2020 10:24 ⋅ Leave a Comment ⋅

The recent activities were dictated by positioning new equipment in the tunnel and forward fuselage.  As a result strict adherence to the sequence outlined in the Vans plans were required, otherwise some installations out of order would be extremely difficult, if not impossible).

The elevator idler arm was deburred, primed and riveted together.  This piece is located in the tunnel between the rear seats and connects the forward elevator pushrod to the mid-fuselage pushrod.

 

 

 

These are photos of the control and flap system parts before fitting, drilling and deburring.  The right picture shows the aileron pushrods which link to the control stick bases.

 

 

 

The control stick bases were reamed for roundness after drilling the control stick itself, then were protected with tape and expandable ear plugs prior to priming the ends.  The brass bushings were then driven into the pivot holes for a snug fit.

 

 

The control column was installed with finger tight stop nuts, then the control stick bases and pushrod assembly were also loosely attached.  After adjusting the length of the pushrod assembly to ensure the control sticks were parallel, all fixtures were tightened and Torque Seal applied.

 

 

Though officially part of the rudder controls, the plastic rudder cable guides were drilled.  They were then attached to the forward tunnel.

 

 

 

This shows the elevator idler arm in final configuration with pushrods attached.  The space was tight for my hands when inserting the bolt, rod end bearing and washers.  A rare earth magnet on the bolt end and washer pliers greatly helped during assembly.

 

 

This jig was created to align the neutral position of the elevators at the bellcrank position. The final configuration was established with later posts on Empennage Attachment.

 

 

 

Posted in: RV-10 Build Project, Section 39, Control System

Rudder Pedals and Brake System (3)

05-Jul-2020 10:09 ⋅ Leave a Comment ⋅

Final connections for brake lines were completed this week.

The parking brake connected with heavy duty stainless lines to the master cylinders on the pilot’s pedals.  The Bonaco coated, flexible lines were then run through the center lever bracket to the copilot side.

 

 

Here are details about the cable lace and rescue tape applied to hold the lines in place.

 

 

 

MISCELLANEOUS

In researching the fuel level sensors, many recommendations were made to replace the regular gasket material with Viton.  Here are pictures of the McFarlane product to be installed at a later date. In addition, I also ordered Viton Fluoroelastomer O-rings for the #8 screws which hold the fuel sensor base plate onto the wing tanks.  These were obtained from McMaster part number 9464K12.

Posted in: RV-10 Build Project, Section 38, Rudder Pedals and Brake System

Rudder Pedals and Brake System (2)

21-Jun-2020 10:49 ⋅ Leave a Comment ⋅

Due to an interference between the original brake lines and the forward tunnel cover, I decided to a redo would be appropriate.

For this attempt at bending, a jig based on the exact firewall geometry was first emulated with coat hangers, then laid out on the workbench.  The wooden constraints matched the indented box and helped make the two 45degrees bends in quick succession align properly.

 

 

The remaining bends were rough bent with the Imperial tube bending tool. The final configurations were carefully adjusted by hand.  Since these were with the ‘hard’ aluminum, the risk of cracking or compressing during the manual operation was minimized.  I am much happier with the final outcome.

 

Here the forward tunnel cover was relieved about 1/2″ from the stock cutout.  Even the new, better fitting brake lines would not fit into the original space.  On the right, the pilot side flexible lines were cable laced together on the workbench.

 

 

Here the rudder pedal / brake assembly is fit into the bearing blocks and bolted to the mount plates.  The flexible lines were hand tightened to check for lines rubbing together. Pinch points will be covered with plastic spiral wrap, then final cable lacing where needed.

 

 

The left photo shows building a cardboard template for cutting ceramic mat insulation for the forward tunnel.  RV10s generate plenty of heat transfer from this location as the engine exhaust pipes are immediately on the opposite side of the firewall.  The right photo shows relieving the stock Vans fuel valve bracket to accommodate the Andair valve and TS Flightlines flexible fuel hoses.  More on both these items later.

 

Posted in: RV-10 Build Project, Section 36, Brake Lines, Section 38, Rudder Pedals and Brake System

Rudder Pedals and Brake System (1)

13-Jun-2020 18:52 ⋅ Leave a Comment ⋅

The continuation from the brake line fabrication is preparation of the rudder pedal system.

The bearing blocks and mount plate were laid out with the corresponding hardware ready for processing.  The blocks appear to be black Delrin (or equivalent).

 

 

 

 

The center bearing block was measured, then drilled with a #10 drill to accept AN3-22A bolts.  The block was then cut in half for later mounting to the rudder pedal brace.

 

 

 

The side bearing blocks were drilled about 1/8″ deep using the mount plates as a template.  The remainder of the hole was completed in the drill press to achieve perpendicular alignment.

 

 

 

A feature recommended by other builders for the side bearing were oil holes added to the bearing blocks. These facilitate lubricating the friction points after installation.  The depth and location are first checked before going to the drill press.

 

 

 

This photo shows the completed bearing blocks after addition of the oil holes. Deburring the Delrin on the inside of the bearing hole required the use of a Dremel tool.

 

 

 

 

Spacers for the lower brake cylinder attachment point were made from AT6-058×5/16 tube. These are sized to accommodate AN3-12 bolts.

 

 

 

 

The main pedal parts were staged for match drilling and preparation for priming (SEM Self-Etch Primer) and final paint (PPG Concept – Boeing Grey).

 

 

 

Parts staged, primed and painted.

 

 

 

 

The brake doubler plates and brake pedal side plates were riveted together to make the brake pedal subassemblies.

 

 

 

 

All the prepared parts and hardware were stage for attachment to the pedal levers.

 

 

 

 

The Vans kit uses Matco brake components.  Here the completed pedals are enhanced with AeroSport pedal extensions 3D imprinted with N190XB.  Next actions are to fit these units into the fuselage, then attach soft brake lines.

Posted in: RV-10 Build Project, Section 38, Rudder Pedals and Brake System

Brake Lines (2)

06-Jun-2020 18:33 ⋅ Leave a Comment ⋅

After bending the under seat lines, the next step was install RattleTrap xTreme sound dampening material and continue with line fabrication.

Because of the adhesive backing on the foil sound dampening (potential fire hazard), that material will only be installed under the seats and rear portion of the tunnel.  Eventually the forward tunnel and engine-side firewall will be covered with Fiberfrax ceramic mat and stainless steel foil.

 

 

Here are pictures of the brake lines installed under the left seat and tunnel.  The material used was 1/4″ diameter ‘hard’ aluminum tubing. Flexible and stainless covered Bonaco lines will be used for the pedal connections, but the idea here was permanently install the fixed lines in static locations. Hopefully they should never need to be removed.

 

 

The bends on the right line were made more complicated than needed, but this line did fit well.  The lesson learned was applied to the left side, where the construction was simplified during the bending process.

 

 

 

The left photo show the AirWard parking brake kit which includes a Matco hydraulic valve.  That right photo is the forward tunnel after the heater plenum was installed with #6 screws.  If in the future the brake lines ever do need replacing, having a removable plenum will make the job much easier.

Posted in: RV-10 Build Project, Section 36, Brake Lines

Brake Lines and Misc (1)

31-May-2020 10:46 ⋅ Leave a Comment ⋅

After many moons of working on body, panel and fiberglass parts, I can now start installation of mechanical components.  First up are the firewall insulation and brake line fabrication.

As usual the brake parts are laid out prior to installation.  Here the standard Matco brake cylinders which come with the Vans kit are supplemented with 3/8″ ID springs and Climax C-037-A aluminum set screw collars.  The springs assist with brake pedal rebound and provide better control during braking.  Since the spring tension is adjustable via the collar, the final alignment can be fixed per desire after some braking tests.

 

The Vans brake plumbing will be augmented with a Matco park valve from the AirWard kit.  The final angles on the AN fittings will be selected for best alignment after the lines are bent.

 

 

 

The firewall on the quick build fuselage comes with the Vans brake line attachment already riveted in place.  This was removed to accommodate the base plate from the AirWard kit.

 

 

 

Since the interior side of firewall will also be covered with Rattle Trap sound dampening and heat reflective material, templates for the insulation material were measured and cut.

 

 

Hard 1/4″ aluminum tubing was selected for the brake line material.  Coat hangers were bent into templates for the under-seat hard lines.  Then the tubes were bent to fit.  Here are the first two examples prior to flanging.  The next steps will be the tunnel lines and connection to the parking brake valves.

 

 

 

GLARE SHIELD

The grab handles on the quick-build glare shield are very flimsy.  Since those holds are intended for passenger entry/egress, I feel some reinforcement is necessary.  Here the holes are measured and cut in a spare piece of fiberglass to add stiffness.

 

 

The final attachment of the reinforcement plate will be with rivets, then covered with 1/8″ closed foam padding bonded together with a covering material for anti-glare purposes.  Most likely this material will be grey trunk liner – thin, strong, and non-reflective.

 

 

 

INTERIOR PAINT

The front seat area paint of the cockpit was fine, but additional work was needed on the back seat/baggage area.  This was mostly due to perspiration drops on some flat areas from the previous work.  I wound up sweating at the end of the original paint session due to the high outside temperature.

 

These cosmetic issues have waited until now for resolution.  Now all the interior paint looks good, including the sills which were not part of the original paint session.

 

 

 

CABLE RUNS / BATTERY PLATFORM

With the time for pulling electrical wires fast approaching, attention is required for the previously installed nylon conduits.  Trimming back the excess length was performed.  Also done was the rivet installation of the secondary battery platform support bracket.

 

 

 

Posted in: RV-10 Build Project, Section 36, Brake Lines