Wednesday, December 14, 2011

Vans Aircraft RV-12 Build, Section 21: Mid Fuse Bibs & Bottom Skins (part 8)

Reference: page 21-14; 1.5 hours

The sachets of parts for the RV-12 aircraft, stored in the garage, are getting smaller (and much easier to search through) while the fuselage is growing in size. Strange to think I picked up the tail kit from Van's Aircraft less than 10 months ago and in that time have built the tail, wings and am well into the fuselage.

Step 1: Secure the WD-1210 Control Column to the two Control Column Mount Assemblies using the hardware called out by Van's Aircraft in Figure 1 on page 21-14.Hardware call-outs are symmetrical about the fuselage center-line. Small tabs of tape can be used to hold the pairs of washers during instillation.

Builder's note: The key is to use the correct number and thickness of washers so the Control Column ears are parallel to the Column Mounts and not bowed in or out. Also, I forced Aeroshell #5 grease down into the bearing cage, as there will never be a better time to access this area. Below you can see a washer holder I made out of a tongue depressor.

Step 2: Dimple the holes in the top flange of both inboard F-120L& -R Step Ribs indicated in Figure 2 of the RV-12 plans on page 21-14.

Builder's note: I had a interesting time dimpling these two flanges, as the holes are very close to the rib web. A small sized #30 female die would have solved the problem. Not having one, I used a highly modified spare die to do the job. I have not experienced this kind of clearance issue on any of the previous rib parts to date on the RV-12.

Step 3: Dimple the sic sets of nutplate attach rivet holes in the top flange of the F-1202F Bulkhead.

Step 4: Rivet the F-1212-L & -R Step to the F-1203A Bulkhead using the rivets called out.

Step 5: As indicated by Van's Aircraft in Figure2, dimple the bottom hole in the forward flange of both outboard F-1212-L & -R Step Ribs and the two corresponding holes in the F-1202F Bulkhead.

Step 6: Cleco (DO NOT RIVET) the F-1202F Bulkhead to the F-1212 Step Ribs.

Step 7: Figure 3 on page 21-14 of the RV-12 plans, shows a bottom view of the fuselage. Install the snap bushings that are called out into the holes of the bulkheads as shown.

Builder's note: Not all of the snap bushings are pictured below . some are in places I couldn't get my camera into. Also in some of the pictures I am pointing at less obvious ones

This completes page 21-14 of the RV-12 plans.

Tuesday, December 13, 2011

Vans Aircraft RV-12 Build, Section 21: Mid Fuse Bibs & Bottom Skins (part 7)

Reference: page 21-13; 4.5 hours

The RV-12 is coming along nicely. I am including a picture of the compressor I bought just in case someone was wanting to know the details. At this point in time I am very happy with it. I am also adding a possible builder Gotcha to the list from step 7 listed below. I didn't have a problem but it could easily catch someone.

Step 1: Cleco the F-1203A Bulkhead Assembly to the front flange of the Seat Ribs and to the front of the F-1253 -L & -R. Seat Floor Supports. In order to align the holes in the seat floor supports with their corresponding holes in the Bulkhead Assembly (the holes just below the F-1203D-L & -R Stub Supports), the seat floor supports need to be bent up slightly at the front of the seat floor.

Step 2: Rivet the F-1203A Bulkhead Assembly to the front flange of each F-1215-L & -R Seat Rib using the rivets called out in Figure 1 of the RV-12 plans. DO NOT rivet the F-1253-L &-R Seat Floor Supports at this time.

Step 3: Dimple the single pair of nutplate flange, and the four pair of nutplate attach holes along the inboard edge attach holes along the inboard edge of the F-1226-L & -R Seat Ramp Floors

Builder's note: I needed to flex the leading edge of the Seat Ramp Floor to get my dimpling set in place. Note use of tape to prevent scrapping of the floor panel.

Step 4: Dimple the single #30 hole on the forward flange, and the four #30 holes along the inboard edge of the Seat Ramp Floors that are called out for flush rivets.

Step 5: As indicated in Figure 2 by Van's Aircraft, final drill 1/2' the forward 3/8" hole in both the -R & -L Seat Ramp Floors.

Step 6: rivet in place the Seat Floors using the rivets called out in the plans on page 21-13.

Step 7: Reach through the lightening holes in one of the Seat Ribs and attach the nutplate to the back of the F-1203A Bulkhead. dimple then attach the four nutplates to the bottom of the Seat Rib flange, and the nutplate to the bottom of the F-1225-R Seat Floor using the rivets called out.

Builder's note: Here is the possible Gotcha. In the picture below there is a lip near the nutplate I am pointing at. If too short of a rivet set is use on the bottom, the lip will be crushed (not a good thing). Make sure the rivet yoke will clear this bottom lip by using a thick rivet set. That's all there is to it. Not much of a Gotcha.

Step 8: To remove the powder coating from the bolt holes in the WD-1210 Control Column, final-drill #12 all of the 3/16" holes and final-drill 1/4" all of the 1/4/" holes.

Builder's note: I used a angle drill to clear the side of the column tubing. I don't know how a regular drill could be used. Also I use a stepped bit for the 1/4" hole to ensure a tight fit with the bolt that will go through it.

Step 9: Insert the Control Column through the lightening holes of the Seat Ribs. If necessary, the F-1253 Seat Floor Support can be carefully bent down out of the way, while inserting the control column.

This completes page 21-13 and today's work session. I came to realize I have not posted any pictures of the RV-12's fuselage as a whole. So I will leave you with these pictures. Enjoy!

Sunday, December 11, 2011

Vans Aircraft RV-12 Build, Section 21: Mid Fuse Bibs & Bottom Skins (part 6)

Reference: page 21-11, 21-12; 4.5 hours

Welcome! This blog details the construction of my RV-12 (and other projects) E-LSA aircraft kitted by Van's Aircraft. This entry is the 6th part of building the fuselage kit. I have to apologize for some of the blurry pictures. I was attempting not to use the camera flash as much.

Step 1 Separate the two sets of F-1230E Bulkhead Doublers by removing the hatched areas shown in Figure 1 of the RV-12 plans on page 21-11.

Where possible, install rivets in the F-1203A Bulkhead with the manufactured heads on the forward side.

Step 2: Rivet the F-1203E-L &-R Bulkhead Doublers to both ends of the F-1203A Bulkhead, to the F-1203C Sub Spar Receptacles, and Sub Spar Receptacle Supports using the rivets called out in Figure 2 on page 21-11 of the RV-12 plans. As indicated in the figure, do not install rivets in the four holes in both sets of bulkhead doublers, or the eight holes in the spar receptacles support outbd of the doublers.

Step 3: Rivet the flange of the F-1203E-L & -R Bulkhead Doublers to each other using the rivets called out in Figure 2.

Step 4: Rivet the Control Column Mount Assemblies (and their associated one-leg nutplates) to the Bulkhead using the rivets called out. No not rivet the two bottom holes in both assemblies

Step 5: Rivet the four nutplates t the sloped flanges of both Control Column Mount Assemblies using the rivets called out.

This completes page 21-11.

Reference page 21-12;

Step 1: Separate the F-1203J Bulkhead Doubler by removing the hatched areas.

Step 2: Rivet the 17 nutplates shown in Figure 2 on page 21-12 of the RV-12 plans, to the Bulkhead using the rivets called out. DO NOT install a nutplate at either end of the top row of nutplates I'm pointing to one of these in the picture below.

Step 3: Rivet the F-1203J Bulkhead Doublers to the Bulkhead using the rivets called out in Figure 2.

This completes page 21-12 of the RV-12. Thanks for looking.

Saturday, December 10, 2011

Vans Aircraft RV-12 Build, Section 21: Mid Fuse Ribs & Bottom Skins (part 5)

Reference: page 21-10; 4.5 hours

This entry continues the construction of the RV-12's fuselage kit. It still doesn't look like an airplane, but it look less like a pile of unrelated parts! Good/Bad news about the compressor. I found the replacement part for the compressor, they will cost about half as much as a new air compressor, however they are more than a month out. So I opted for a new 60 gallon unit from Home Depot. It is an oil compressor and much quieter than my old oil-less unit.

Step 1: Carefully deburr the edges and holes of the F-1233A Control Column Mount Spacer and the F-1223B-L & -R Control column Mount Brackets so that the parts will fit together tightly.

Builder's note: Be very careful not the over deburr the holes! As the bearing need to fit tight. Also in the picture below you can see my center parts were slightly curved and needed to be straightend.

Step 2: Machine countersink the four holes surrounding the bearing holes in the Control Column Mount Brackets. Machine counter sink flush on the outboard sides of both brackets for double-flush rivets. Machine countersink the two sets of nutplate attach rivet holes in the sloped flanges (flush on top.)

Step 3: As shown in Figure 1 of Van's Aircraft plans on page 21-10, sandwich the bearing and the control Column Mount Spacer between the Control Column Mount brackets then rivet the parts together. The hole indicated in the spacer locates the top of the part.

Step 4: Separate the F-1203B Bulkhead Flange by removing the hatched area shown in figure 2 of the plans.

Step 5: Seperate the F=1203D Stub Spar Receptacle Support by removing the materil shown.

Step 6: Machine countersink all of the #40 nutplate attach rivet holes and the sic #30 holes in the areas indicated in the RV-12 plans. Machine countersink the #30 holes 120degree NOT the standard 100 Degree!

Step 7: As shown in Detail A of the RV-12 plans page 21-10, drill the four 1/8 inch holes to the sizes indicated and remove the hatched area from the 7/8 inch hole to make it completely circular. The hatched area can be removed by snipping between the small holes using wire cutters, then finishing with a round file.

Step 8: Rivet the F-1203B-L Bulkhead Flange to the left aft side of the Bulkhead. Repeat this step for the right side of the bulkhead using the F-1203B-R.

Step 9: File the curved recess of both F-1203C Stub Spar Receptacles (the bevel locates the top of the part) to closely fit the rounded mating ends of the Stub Spar Assemblies of both wings. Once filed, mark the parts so that they will be assembled on the side they were fitted to.

Step 10: Cleco the Stub Spar Receptacle and the Stub Spar Recepetacle Support to the Bulkhead as shown in Figure 5 of the plans. Rivet the parts together using the two rivets called-out. Final drill #30 any holes too tight to accept a rivet. Builder's note: On my parts that was all the holes! Repeat this step for the right side of the bulkhead.

That's it for today! This also completes all of the steps on page 21-10 for the RV-12.