Tuesday, July 29, 2014

Vans Aircraft RV-12 Airplane Build, Section 42C: Skyview Update (part 9) & Service Bulletin 13-12-12

Reference for this entry: pages 42C-09, Service Bulletin 13-12-12; 6.0 hours

Today I will be working on the new ADAHRS stiffener for the Dynon Skyview. It goes in the tail cone of the RV-12 airplane just infront of the AHARS modual. Also this the day I choice to work on the SB 13-12-12 or sealing the avionics bay on the RV-12.

Reference: Page 42C-09:

Step 1: Counting from the aft most rivet remove the tenth rivet from the F-1283C J Stiffener. then cleco the stiffener to the J Stiffener wehere the rivet was just removed.

Step 2: Align the ADAHRS Stiffener perpendiculary to the J-Stiffener.

Step 3: Match-Drill #30 the holes in the Stiffener into the Top Skin . Deburr all of the holes.

Step 4: Blind rivet the ADAHRS Stiffener to the J_Stiffener and Top Skin from outside of the fuselage.

This completes Page 42C-09 and the installation of the ADAHRS Stiffener.

Reference: SB 13-12-12

Step 1. Remove, if/as required, the F-1240 Upper Forward Fuselage Skin and apply a release agent to the area of the F-1240 which mates to the F-1201H Upper Fwd Fuse Doubler.

Builder's note: I put aluminum tape (electrical would have been better) on the openings on the sides panels so I could seal these as well.

Step 2. Apply approx. 1/16 diameter bead of sealant (see above) to the entire length of the F-1201H Upper Fwd Fuse Doubler.

Builder's note: The service bulletin calls out using Black silicon or equilvalent. So I used fuel sealant with good results.

Step 3. Install (or re-install) the F-1240 Upper Forward Fuselage Skin and allow sealant to cure.

During this time I also sealed the steps to the fuselage.

That's it for today's work on the RV-12 airplane by Van's Aircraft.

Sunday, July 27, 2014

Vans Aircraft RV-12 Airplane Build, Section 33: Miscellanea (part 1)

Reference for this entry: pages 33-02, 33-03, 33-04; 3.0 hours

Today I will start Section 33 for the RV-12 airplane. It's a section I jumped over earlier. But hay, there is no time like the present.

Step 1: Dimple the nutplate rivet holes in the Seat Floor Cover and the nutplates called out by Van's Aircraft. Rivet the nutplates to the floor covwer.

Step 2: Installing Flap Detent Bracket. On hold until later.

Step 3: Attach the end fitting of the lap belts to the Seat Attach Lugs using the called out hardware.

Step 4: Attach the end of the crotch straps to the Strap Lugs using the called out hardware.

Reference: 33-03

Step 1: Attach one end of the Shoulder Harness Cables to the Shoulder Strap Lug. No bushing are needed at this end.

Step 2: Attach the other end of the Shoulder Harness Cables to the Shoulder Harness. The bushing will allow the end fitting to rotate freely.

Step 3: Make the left and right Rudder Pedal Access Covers by removing the connecting metal between them.

Step 4: Dimple the nutplate rivet hole locations in the Rudder Pedal Access Covers and in the nutplates. Rivet them to the Access Covers.

Step 5: Install the Rudder Access Covers using the called out hardware.

Step 6: Cut the MS21266-1N Grommet to 2 13/32 inches and install on the Tunnel cover.

Step 7: Installing the tunnel cover will be done later.

Step 8: Dimple #19 the holes in the Baggage Cover as shown in the RV-12 airplane plans.

Reference: Page 33-04

Step 1: Test fit the Ant-abrasion Strip on the Mid Fuse Brace. With an ultra-fine felt tip marker and a striaght edge, make a line on the top of the brace as shown on page 33-04 of the RV-12 plans.

Step 2: Install the Anti-abrasive Strip, on the clean and dry mid-fuseBrace.

Builder's note: Nothing sticks well to the textured paint I used on the interior. So the bottom edge tends to pop loss when it is warm outside. So I will use Pliobond to stick it down. This section will be completed later in the finishing of the RV-12 airplane.

Saturday, July 26, 2014

Vans Aircraft RV-12 Airplane Build, Section 31A: Wing Electrical Interconnector Update (part 5)

Reference: Pages 31A-04, 31A-05; 6.0 hours

Again I find myself working on the wing lighting wiring for the RV-12 airplane.

Reference: Page 31A-04

Step 8: On the left wing use the string previously installed to pull the Strobe Power Wire, Strobe synch Wire, and another string from the wing root into the wing tip. Repeat on the other wing.

Step 9: Attach all the crimped wires called out in Figure 1 on page 31A-05 to the Floating 8 Pos Connector Male. On the back side of the connector is a number for the wire position.

Step 10: Attach all the crimped wires called out in Figure 2 on page 31A-05 of the RV-12 airplane plans to the Floating 8 Pos. Connector Female.

This completes page 31A-04.

Reference: Page 31A-05>br/>
Step 1: On the left wing attach the ring terminal end of the Terminal Ground Wire to the Nose Rib and then repeat for the right wing.

Step 2: Install the Floating 8 Pos Connector Male and Female to the Standoffs.

This completes page 31A-05 and this work session on the RV-12 airplane.

Friday, July 25, 2014

Vans Aircraft RV-12 Airplane Build, Section 31A: Wing Electrical Interconnector Update (part 4) & Section 40 Lighting Kit

Reference: Pages 40-08, 31A-04; 2.0 hours

Today's work on the RV-12 airplane is a combination of installing the wing tip lights and the new wing connection system. I will say some of these wire runs would have been much easier to install back when the other wiring was going into the wing.

Reference: page 31A-04

Step 4: Fabricate two WH-B203 Strobe Power Wires 153 inches long from 18 gauge wire.

Bold Step 5: Fabricate two WH-B318 Strobe Synch Wires 153 inches long out of 18 gauge wire.

Step 6: Strip one end of all the fabricated wires then crimp on a interconnector pin.

Step 7: NA (tip lights have not been installed) Remove the Wing tip Nav Lights and pull the male Molex connector housing through the oval shaped hole in the wing Extensions.

Reference: Page 40-08

Step 1: Using the dimples molded in the face of the Extensions to align the Wing tip lIght mounting Brackets. Clamp the bracket in place then match dril#27 the holes in the mount brackets into the extensions.

Step 2: Done previously Remove the material from inside the oval area on the extensions to the scribed line.

Step 3: Machine countersink 120 degree all attach holes in the upper flange of the Extensions for the head of a CS4 rivet. Finish the edges of the part.

Step 4: Attach the Wing Tip Light bracket using the called out hardware.

Step 5: Make two WH-B211 Nav/Strobe Ground Wires 6 inches long from 18 gauge wire. Attach a ring terminal on one end and a female Molex pin on the other of each wire.

Step 7: Trim and strip the WH-212 Nav/Strobe Power Wire in each wing tip to match the length of the Ground wires. Crimp a female Molex pin onto the end of each nav/strobe power wire.

This completes today's work on the project. I have jumped over a few steps but these will be completed in the next few entries.

Tuesday, July 22, 2014

Vans Aircraft RV-12 Airplane Build, Section 31A: Wing Electrical Interconnector Update (part 3) & Section 40 Lighting Kit

Reference: Pages 40-07, 31A-02, 31A-03, 31A-04; 3.5 hours

Today's entry will soon be outdated, as my RV-12 airplane came with the old style e wing interconnect. This old style is being updated on my airplane and will of course be standard equipment. Just bare with me through the process.

Reference: Page 31A-02

Step 2: Remove the three screws on the W-Terminal Bracket on both wings.

Step 3: Make sure all the wires are labeled.

Step 4: Cut the ring terminals connected the the Terminal Blocks.

Step 5: Push the cut wires modified in step 4 through the snap bushings in the first nose rib.

Step 6: Set aside the two Terminal Ground Wires for later.

Step 7: Remove the snap bushings from the Nose Ribs and insert a snap bushing into the Wing Electrical Template.

Step 8: Tape three washers together that say "Tape Here" in the figure 3 drawing on page 31A-02.

Step 9: Screw the Wing Electrical Template to the Nose Rib. Make sure the template is flush to the nose rib stiffening bead and parallel to the web of the nose rib.

Step 10: Match-drill #30 the hole that says "drill here First" in figure 3 on page 31A-02 of the RV-12 airplane plans.

After match drill that hole, slide washers behind the template and cleco match-drill #30 the remaining active holes show in figure 4.

Step 11: Remove the snap bushing and wing electrical template from the nose rib. Repeat the drilling on the other wing.

This completes page 31A-02.

Reference: Page 31A-03

Step 1: Reinstall the snap bushing ino the Nose Rib on each wing.

Step 2: Cleco and rivet a Doubler Plate to the Nose Rib on both wings.

Step 3: Attach the Standoffs to the inboard most NOse Rib on each wing.

This completes page 31A-03.

Reference: Page 31A-04

Step 1: Pull the wires back through the snap bushing in the Nose Rib.

Step 2: Strip the wires pulled back through the snap bushing and crimp on an ES-00079 Floating Connector Pin 16-20 AWG.

Step 3: Strip the cut end of the two terminal Ground Wires and crimp on a pin.

Reference: Page 40-07

Step 1: Trim the W-1222-L & -R Extensions back to within 1/16 of the scribe lines defining the part perimeter with a hand shear, then sand the extensions back to the scribe line.

Step 2: Fit the W-1222-L & -R Extensions to each wing tip then drill #30 the forward two and aft two holes into the upper flange and the W-1204E-L & -R Fwd Wing Tip Ribs. Remove the extensions and clear any drill chips then cleco back in place. Drill #30 all the hole locations into the lower flange and into the W-1204D Wing Tip Close-Out. Match-Drill #30 the three holes already in the wingtip (a bright light may help in revealing the hole locations underneath the fiberglass).

Step 3: Cover each wing tip in the area around where the flox on the W-1222-L & -R Extensions will touch with a release agent such as car wax. See Figure 1 and Figure 2. Add a glob of modeling clay or wax to the area where a nut will be placed (see Figure 1 and Figure 2).

Builder's note: I used packing tape and mold release with good results.

Step 4:NA as my wings are in a stand. Turn both wings upside down.

Step 5: Prepare approximately 2-3 fluid oz. of flox/epoxy resin mixture. Mix in flox until the concoction is just thick enough to not pour from the cup.

Step 6: Fill cavities in the upper flange of the W-1222-L & -R Extensions that abut the W-1204E-L & -R Fwd Wing Tip Ribs with flox/epoxy resin mixture, then cleco the extensions to the F-1204D Wing Tip Close-Outs. Immediately clean any flox/epoxy resin mixture that may have squeezed out.

Step 7: When the flox has set up, drill #30 the top center two holes into the W-1204E-L & -R Fwd Wing Tip Ribs.

Step 8: Remove the W-1222-L & -R Extensions from each wing tip. Sand away any of the flox that may have squeezed out around the perimeter of the part. Remove the modeling clay plug.

This completes page 40-07 and this entry into the RV-12 aircraft builder's log.