Friday, April 29, 2011

RV-12 Section 14 Rear Spar, Stub Spar, Hinge Brackets (Part 1)

Reference: page 14-02; 1 hour

This entry starts the preparation the RV-12's "other" wing spars. It not a very long section.

Step 1: Cleco one W-1208B Stub Spar Doubler to each of the W-1208C-L & -R Stub Spar Channels, on the outer web (opposite the direction that the flanges are bent.) Mark the stub spar doublers as left and right per call out. Refer to the stub spar doubler and channel as the Left and Right Stub Spar Assembly.

CAUTION: Avoid using a dimple as a guide for the countersink depth. The dimple may prevent the skin from laying flat even when the coutersink is too large.

Step 2: machine countersink 120 degree the W-1208C-L & -R Stub Spar Channel, per plans, on the outer surface of all the holes in both flanges as called out. Drill a 1/4 inch hole in a thin piece of scrap aluminum to make checking the maximum diameter of each countersink easy.

Builders note: I don't have a picture of the gauge I used. Also I found using a micrometer was easy as well.

Step 3: Machine countersink 100 degree the three holes at the inboard end of the Stub Spar Assembly to fit the head of an AN426AD3 rivet.

Tuesday, April 26, 2011

RV-12 Spar Assembly (Part 2)

Reference: page 13-02; page 13-03; 3.5 hours

Today's entire will complete the assembly of the RV-12 wing spars.

Step 3: Cleco the second row of holes in the W-1210B-L Left Rib Doubler to the W-1206K Attach Angle, which is part of the W-1206-L Spar Assembly, at the inboard end of the spar channel.

Step 4: Using an extended #30 drill bit, match-drill the first row of holes of the W-1210B-L Left Rib Doubler into the W-1206K Attach Angle as shown.

Remove the Left Doubler, deburr, then set aside the left and right rib doublers until Section 15, Page 3.

Step 5: Drill and tap the 19/64" holes in the AEX Tie Down on both W-1206-L & -R, Spar Assemblies.

Builders note: The plans figure make it look like the top and bottom of each tie down needed to be taped. I only tapped the bottom of both. As I can see no reason to tap the top of these. If I am wrong I will post about it before skinning the wings.

This completes page 13-02.

Reference 13-03

Step 1: Cleco the W-1206V Attach Angles to the W-1206-L & -R Spar Assemblies as shown in plans. Orient all of the attach angles so the short flange, that contracts the web of the spar assembly channel, points inboard.

Step2: Cleco the W-1206T Attach Angle to the outboard end of the W-1206-L & -R Spar Assemblies.

Step 3: Rivet the W-1206T Attach Angle to the W-1206-R Spar Assembly channel. Rivet the inboard most W-1206k Attach Angle, which comes attached to the right spar assembly, to the W-1206B Spar Stud Doubler.

Step 4: Rivet all of the W-1206V Attach Angles to the W-1206-L & -R, Spar Assemblies. Rivet the W-1206T Attach Angle to the left spar assembly.

Step 5: Rivet the W-1206-L & -R, Spar Assemblies at the remaining holes marked with rivets called out in plans.

Builders note: for these three holes confirm the correct rivets are used. These are LP4-4.

This completes both page 13-03 and Section 13 Spar Assembly of the RV-12 airplane wings.

Sunday, April 24, 2011

RV-12 Spar Assembly (Part 1)

Reference: page 13-02; 2.0 hours

Step1: Seperate the W-1206V and W-1206T Attach Angles by removing the joining material.

Step 2: Mark, then separate the W-1210B Rib Doublers by removing the joining material.

Builders note: The parts were then etched and alodined before priming.

Saturday, April 23, 2011

RV-12 EAA Technical Counselor's Inspection

I haven't gotten much done on the RV-12 airplane kit, due to work and school. However, the RV12 fuselage and finishing kit have both been inventoried with no surprises. Also, Jake, our EAA technical counselor, from the EAA chapter stopped by to check on the airplane project. There were none concerns or problems to report and he is very pleased with the progress so far. It is great to have a second set of eyes looking at the plane and Jake is a great resource as he has build several of Van's aircraft including a RV-12. After the inspection the tailcone parts were packed up and moved to storage.

Tuesday, April 12, 2011

RV-12 The Case of the Missing Aileron/flapron Nose Ribs

Unpacked and inventoried the wing kit for the RV-12 airplane this weekend. All was well packed, however I was "missing" 4 flaperon nose ribs (part number A-1204-L and A-1204-R.) In talking with Van's Aircraft said they get this call about missing these ribs from time to time. The ribs are packed inside two other parts in the wing sub-kit #5. Sure enough they really are there, just hiding! See the picture below.

One other thing I ran accross was in hardware bag 2622. The inventory and the bag both list 12 ea. K-1100-06 contersunk nutplates. Instead I found standard K-1000-06 nutplates. So if your wing kit shipped sometime around mid-March 2011, it would be good to check the nutplate in that bag out. In the picture below the correct nutplate is on the left with the incorrect plate as shipped on the right.

Van's Aircraft has since pulled the affected hardware bags out of inventory.

Monday, April 4, 2011

RV-12 Tailcone (Part 11) Completed

Reference: page 10-10; 4.5 hour

This entry finishes the tailcone for the RV-12. During the construction, I had time to think about completing section 11 and 12 of the plans. I going to hold off on these two sections and jump into building the wings since I have already picked up the wings from Van's Aircraft. Not to mention the tailcone will be easier to store without the tail feathers attached.

Step 10: Rivet all of the remaining, unmasked open holes in the Tailcone Assembly.

This completes page 10-10. So far I have 101.5 hours into the project, but keep in mind etching, alodining and priming adds a lot of time. But in my mind it will be worth it. So far I have really enjoyed building the RV-12 and am excited about flying this fine Light Sport Aircraft.

Saturday, April 2, 2011

RV-12 Tailcone (Part 10)

Reference: page 10-09, 10-10; 6 hours

Setp 5: Rivet the F-1238_L Snap Bushing Bracket to the F-1279-L Upper Left Skin using the rivets called out.

Step 6: insert the snap bushing into the F-1238-L Snap bushing Bracket.

Step 7: Route a string from the forward end of the existing structure to the F-1211 Assembly. The string will go though the F-1238-L Snap Bushing Bracket, out through the left rudder control cable cutout, the back in through the right rudder control cable outout and structure. Tape both ends of the string to the inside surface of the bottom skin.

Step 8: Place masking tape over all of the holes that are within seven inches of the forward edge of each tailcone skin. The masked holes will be left oopen for the remainder of this section.

Step 9: Rivet all of the open holes of the F-1280-L & -R Left and Right Side Skins. Rivet only the holes in the F-1279-L & -R Upper Left and Right Skins that are common to the left or right side skins. Capture the F1211C Hinge Bracket when riveting the aft end of each left and right side skin.

This completes page 10-9 of Van's Aircrafts plans.

Reference page 10-10

Step 1: Final-Drill #19 the screw holes of the F-12106 Fwd Skin Rib per call-outs.

Builders note: I've been using the hole deburr pictured above. with good results. It was purchased from Cleveland Aircraft Tool.

Step 2: Dimple #8 the screw holes of the F-12106 Fwd Skin Rib per call-outs.

Builders note: As you can see in the picture above the female die has been modified so as to not damage the web on the rib.

Step 3: Dimple 3/32 the nutplate attach holes of the F-12106 Fwd Skin Rib.

Step 4: Dimple 3/32 the nutplate attach holes of eight K1100-08 nutplates.

Step 5: Rivet the dimpled nutplates to the F-12106 Fwd Skin Rib using hardware called out.

Step 6: Guide the F-1210B Plate through the slot in the F-1278 Top Skin. Cleco the Top Skin to the F-1210 Frame. Match-Drill #30 the two outboard-most holes in the F-1210C Angle using the Top Skin as a guide. Check the top skin for deformations caused by the F-1210C Angle at the locations called out. Remove the top skin. Deburr the angle. If deformations were present in the top skin file material from the angle to minimize deformations on the top skin. Cleco the top skin to the F-1208, F-1209 and F-1210 Frames and F-1279-L & _R Upper Left and Right Skins.

Step 7: Rivet the F-12106 Fwd Skin Rib to the F-1278 Top Skin.

Step 8: Cleco, then rivet the F-1283C J-Stiffener to the F-1278 Top Skin as shown.

Step 9: Place masking tape over all of the remaining open holes that are within seven inches of the forward edge of the top skin.