Sunday, July 31, 2011

Vans Aircraft RV-12 Build, Section 18: Flaperon (part 1)

Reference: page 18-02; 4.5 hours

This entry starts the assembly of the flaperons for the RV-12 airplane kit manufactured by Van's Aircraft and gets into so "serious" metal fabrication. During this section I built both the right and left flaperons at the same time.

Step 1: Make the A-1207-L Actuation Brackets from AA6-125 X 1 1/2 X 2 X 10 as shown in Figure 1 on page 18-02 of the RV-12 plans. Make the A1207-R Actuation Bracket which is the opposite of the A-1207-L Actuation Bracket.

Step 2: Make four A-1206 Pivot Brackets from AEX Tie Down as shown in Figure 2 of the RV-12 plans by Van's Aircraft.

That's it for today's work. I hope the picture sequence is helpful.

Saturday, July 30, 2011

Vans Aircraft RV-12 Build, Wing Moving Day

With the wings all but done, I have held off on installing the wing tip lights, it is time to move them into storage. For this I built a wing stand based on the EAA's design. Here's a picture of it without the carpet straps. If you would like a PDF of the design here is a link: EAA Wing Stand

Then it was on to moving the wings. I didn't want to fool with the trailer so I loaded them on my truck one at a time. Pallets and foam pad were used to set the ride height and protect the wings from the straps and pallets.They traveled very well for the 9 mile trip to storage.

I didn't include any of the time for this in the build time. The garage is looking a little empty so it must be time to bring in the fuselage kit.

Tuesday, July 26, 2011

Vans Aircraft RV-12 Build, Section 17: Wing Skins (part 12)

Reference: page 17-06; 1.5 hours

Step 3: Cleco the W-1204H-L Wing Tip Trailing Edge to the W-1204D-L Wing Tip Close Out and to the W-1213-L Tip Rib. Clamp a straight edge on top of the W-1204B Wing Tip Aft Skin and confirm that the wing tip tailing edge is parallel to the trailing edge of the wing as shown in figure 4 of Van's Aircraft plans for the RV-12. When satisfied with the plaecment, match-drill #30 the wing tip trailing edge to the wing tip aft skin. Rivet the wing tip trailing edge to the wing tip rib, and wing tip close out.

I didn't get any pictures of checking the wing tip being parallel.

Step 4: Repeat Steps Pg 17-05 Step 1 through Step 3 on this page for the right wing. Builder's note: This step was completed at the same time, as I built both wings simultaneously.

I also notices some of the rivets bottom out on the rivet from the opposing side. An example of this can be seen in the picture below. For these rivets I used a manual rivet puller and slowly pulled the rivet as I slide the rivet flush with the metal.

This completes the building of the wings for the RV-12. Next will come the flaperon construction. Stay tuned!

Wednesday, July 20, 2011

Vans Aircraft RV-12 Build, Section 17: Wing Skins (part 11)

Reference: page 17-05, page 17-06; 3.5 hours

I'm enjoying working on the RV-12's wing tips, it's quite different from the fiberglass tips used on the RV-10 and other Van's Aircraft planes.

Step 4: Rivet the W-1204F-L Aft Wing Tip Rib to the W-1204A-L Wing Tip Fwd Skin and W-1204B Wing Tip Aft Skin. The tip of the Rear Spar Assembly may be trimmed to eas fitting between the flanges of the Aft Wing Tip Rib.

Step 5: Flute the W-1204E-L Fwd Wing Tip Rib so that it matches the outboard edge of the W-1204A-L Wing Tip Fwd Skin. Rivet the fwd tip rib to the wing tip fwd skin and W-1204F-L Wing Tip Rib.

Builder's note: In the picture above the top tip rib has yet to be fluted as compared to the flute rib.It can't be seen in the picture but I had to flute both the top and bottom flanges to get these to fit right.

This completes page 17-05.

Reference page 17-06

Step 1:
Fabricate a bending tool from a piece of wood 1/2 - 3/4 inches thick. See Figure 1 of Van's Aircraft RV-12 plans on page 17-06. To use the bending tool, slide the slot in the bending block over the tab so that the edge of the tab hits the back of the slot and bend the tab. This will give the proper flange height. Bend the tabs of one of the W-1204D Wing Tip Close-Outs as shown in figure 2 of Van's Aircraft plans.

Builder's note: The plans give angles within a degree. I bent mine within 5 degrees of these measurements erring on the less bent side of the measurement with no problems in fitting the close-out

Step 2: Cleco the W-1204D-L Wing Tip Close-Out to the wing. Check to be sure that the fit is good and adjust the bend angles of the wing tip close-out tabs if/as required. When satisfied with the fit of the wing tip close-out, rivet to the wing.

Builder's note: A couple of the rivets bottomed out on the rivets from the opposing skin. For these I used a hand rivet gun to allow these to be slide into place while setting.

Builder's note: If installing lights the rivet holes I am pointing at , in the picture below, are left open until the light fairing is installed.

Next time we will finish the RV-12's wings off with the exception of installing the tip strobe fairings. I'm holding off on these until I start in on the fiberglass work. Also, I don't have the fuel tank sealant and don't want to store it as it has a limited shelf life.

Tuesday, July 19, 2011

Vans Aircraft RV-12 Build, Section 17: Wing Skins (part 10)

Reference: page 17-05; 2.5 hours

Today I only got one step done, however I spent most of the time working on how to handle the wing tip close out on the RV-12.

Step 3: Rivet the W-1204B Wing Tip Aft Skin and the W-1204A-L Wing Tip Fwd Skin to the wing.

Builder's note: This is where I started playing with the front corner of the wing tip. The next two pictures below are different treatment for the tip. The first is of Vans Aicraft's factory plane.The second is of Larry Geiger's beautiful plane which was taken at AirVenture in 2010. He used epoxy and fiberglass to build it up. Both methods work, but I wanted something in between these extremes.

Below are photos of the steps I went through to come up with a formed aluminum tip. As you can see the closout tabs are bent with a curve on the front tabs as opposed to the factory angles.

If messing with forming aluminum is of interest to you, practice on scrap first. Also, a really good resource is Kent White the Tinman
Here's a link to the DVD I have from him: Basic Damage Repair on Aluminum Body.

Monday, July 18, 2011

Vans Aircraft RV-12 Build, Section 17: Wing Skins (part 10)

Reference: page 17-04, page 17-05; 2.5 hours

I've been build both wings on the RV-12 aircraft at the same time, which has worked out very well. 

As a side note, Van's Aircraft has posted pictures of the new Dynon Skyveiw installation on their Facebook page. Here is a link if you have not seen it: RV-12 with Skyview .

Step 4: Cleco the remaining portion of the Outbd Wing Skin and the Mid Wing Skin to the wing. Rivet the outbd and mid wing skins to the wing leaving open holes shown in Figure 3 on page 17 of the RV-12 plans by Van's Aircraft.

Builder's note: I found it helpful (at least on my wings) to set and rivet the rivets in the wing ribs from the nose towards the main spar.

Step 5: Flip-over the left wing placing it upside-down on the table. Dimple the screw holes in the Mid Wing Skin and in the Access Hatch. Dimple the rivet holes in both the nutplates and in the mid sing skin for the access hatch. Install nutplates on the wing skin and install the hatch.

Builder's note: Used small female die during dimpling, however a regular sized die can be modified as well.

Step 6: Repeat all steps from page 17-02 Step2 through Step 4 on page 17-04. Builder's note: As mentioned earlier, I built both wings at the same time so this step is completed. Building both wings has worked fine if you have the space.

This completes page 17-04

Reference page 17-05

Step 1: Take the W-1204G-L HandHold and bend where the part is notched.

Builders note: Used a block of wood with a radiused edge to make these bends.

Step 2: Rivet the W-1213-L Tip Rib to the rear spar . Rivet the Hand Hold and W-1204C WIng Tip Bottom Skin to the wing.

Builder's note: I drilled out and reversed the rivet in the picture above. This was done to give the handle a cleaner look.

That's it for this building session.

Sunday, July 17, 2011

Vans Aircraft RV-12 Build, Section 17: Wing Skins (part 9)

Reference: page 17-03, page 17-04, page 40-02; 7.5 hours

Primed the wing tip parts for the RV-12. Also I'm just about finished skinning and riveting the wings.

It's been just six months since I picked up my RV-12 tail kit from Van's Aircraft. Even with the extra work of prepping and priming the parts it is truly amazing how quickly this airplane goes together. After I finish the wings I'll do a time comparison between the RV-12 and the RV-10.

Reference: page 17-03

Step 5: Layout and then remove the shaded area from the W-1204D Wing Tip Clouse-Out using the template on page 40-17 of the RV-12 plans. This will create a wing tip access opening to reach into the wing tip and routing wires.

Step 6: Drill #19 a hole near the froward edge of the acess opening in the Wing Tip Close-Out. Builder's note: I drill the holes #30 and will enlarge it to final size before installing.

This completes page 40-02.

Reference page 17-03

Step 5:
Cleco the Outbd Upper Skin to the wing skeleton . Rivet the outbd upper wing skin to the skeleton leaving open the holes shown in Figure 4 of Van's Aircraft's plans for the RV-12.

Builder's note: I got over zealous in riveting the left wing's outer panel in place and will need to drill out a few rivet to install the center skin. Ideally the leading edge skin should not be riveted yet. The right wing is done according to the plans.

This completes page 17-03

Reference 17-04

Step 1: Cleco one of the W-1202B Mid Upper Wing Skins to the wing skeleton. Rivet the mid upper wing skin to the skeleton leaving holes open as shown in figure 1 of the RV-12 plans page 17-04.

Builder's note: In the picture above you can see the problem I ran into because of riveting the nose skins on the left wing. The pictures below show how I ended up fitting the skin without drilling out too many rivet. The key was not to force the skins back in such a way as to kink the sheets but to let them arch gradually.

Step 2: Dimple the three inboard holes in the W-1201C-L Wing Walk Doubler shich are in line with the two rows of holes in the leading edge which are already dimpled.

Note: It may be necessary to make a slight edge bend to the forward edge of the Wing Walk Doubler.

Step 3: Cleco the Wing Walk Doubler to the wing. Begin clecoing at the forward/lower edge of the wing walk doubler and progress up and aft. Cleco the remaining portion of the Inbd Wing Skin to the wing skeleton. Rivet the wing walk and inbd wing skin to the wing. Be sure to use flush-head rivets in the dimpled holes.

Builder's note: As my fingertips were getting sore, I started using the dowel rod for placing the rivets into place. Care must be used so as not to dent the skins!

That's it for today's entry. Next time I'll finsh the wing skins and get into the wing tip and closeouts.