Sunday, November 19, 2017

Priming in high humidity

This week has been about priming.  Priming in high humidity is not a good thing because the air compressor tends to force that moisture out of gas and into liquid...right about the time it hits the spray nozzle on my paint sprayer.  This moisture either drips on the aluminum I'm trying to prime or it fans out into a nasty mist that speckles the aluminum.  Either way the primer will not stick to aluminum that is wet.  So, I have to go back, clean up the poorly adhered primer and then re-prime the aluminum.  It doesn't look good, which is ok for priming, but it definitely adds time to the project that doesn't need to be.  So, I did a little work to the air supply for my paint gun. I put a new moisture separator in line and I replaced the small moisture separator that I screw on to the base of my gun.  Between these two steps I seem to have got the moisture under control.  All in all it took 3 priming sessions to get everything primed.

Beside the priming marathons this week I did get a little work on the wings done.  The tie down ring attach points are riveted on.  The ribs are riveted on the right wing and I'm getting ready to put the rear spar on the right wing. 

Wing tie down mounting points installed.  Still need to attach some brackets on the back side for the aileron controls.
Round 2 of rib priming

Yea, figured a selfie was due.
Flap hinges riveted to the wing ribs.

Torque tube for control linkage riveted on the inner most wing rib.

I was having a bit of an issue with some of the rivet holes lining up so I got out the wing skin and cleco'd it in place to see if the rivets were ok...all OK.

After I riveted the wing ribs to the main spar I was looking at the rivets when I noticed this pretty cool view.  Reminds me of those infinity mirrors.

Sunday, November 12, 2017

Main Spar work

This week Amy came home so I spent a little less time in the garage and a little more time with her.  Not too many pictures this week because I've been doing a lot of main wing spar and related parts prep.  This means lots of deburring, countersinking, priming, and many other un-picture friendly tasks.  I did try something new this week though.  I have to prime the large countersunk holes in the main spar to protect the freshly cut aluminum.  Rather than try to brush or spray with my regular priming tools I decided to try a detail air brush.  I was amazed at how nicely this works for small spot priming tasks.  I used very little primer and got a nice thin layer of primer on each hole.

I managed to get all 30 wing ribs prep'd for primer this weekend.  Drilling, deburring, edge straightening and scuffing...long weekend.  I only got half the ribs primed Sunday evening so I will have to have at least one or two more priming sessions before I can move on to the wing skins.

This is a picture of the primed countersunk holes where I used the air brush.  You can see the nice even spray pattern around the hole.
Using the de-burring wheel on my p-grinder to clean up some edges and holes.  There are 30 of these little devils to work on.  These ribs alone took most of the weekend.

Using the tool I built last year to true up the edges to 90 degrees.  
A few of the ribs ready for some touch up priming.

Sunday, November 5, 2017

final tail cone details....I think

This week I have been doing a few little chores in the tail cone.  Things like install the static ports, ventilation ducts, and ELT mount. Then I loaded the entire tail cone into the back of the truck and took it to the hangar in Puyallup where it will stay until I need to attach it to the fuselage...probably at least a year from now. 

On a side note it started snowing already this year.  We have about 3" inches of snow on the deck last time I looked.  Crazy weather.

Glued in and taped so it doesn't move until the epoxy sets up.
Here it is from the outside.

Both static ports are epoxy glued in and being held in place by the wooden sticks.
Tail cone "stored" in the overhead at the hangar until I need it again.  Thanks to Harry for helping me get this thing hung up there.

And now the wings begin.  These are the main spars, an aft spar and some other misc wing parts.  The wings on the 10 are a bit bigger than the wings on the 9 so its going to get tight in this little work shop.  I may have to take my divider wall down to get enough room to work on both wings at the same time.
Just for fun I thought I would throw this one in.  This is a picture from my security camera after dark.  I do have an LED light in the corner that is showing the light you see.

Sunday, October 29, 2017

Tail cone is almost done...for now

This week Amy is out of town on her grand trip to Paris with her kids so I got to spend a bit more time in the shop working on the tail cone.  I made some pretty good progress.

Tail cone cleco'd together and ready to rivet the side skins/stringers.

Oh yea, I ordered a gallon of primer from Aircraft Spruce early this month.  After lots of delays it finally showed up this week and this is what I saw when I opened the box.  Azko is very smelly stuff so you can see there was a small amount starting to leak out of the sealed plastic bag.

And this is what it looked like when I pulled the bag out of the box.  

And finally when I removed the plastic bag....what a waste.  Aircraft Spruce is sending me another batch and they filed a claim with UPS but this was a mess to deal with.

Here you can see the backplate that I am using to do the back riveting.  I have to tilt the tail cone precisely for each rivet on the rounded edge.  You can also see the 2x2 fixed in my vice that I used to brace the edge of the tail cone once I got it at the correct angle.

Speaking of correct angles for back riveting....this is how I knew my angle was correct.  I put this small round spacer next to the rivet I was getting ready to smash...then I tilted the structure until the round spacer lined up with the rivet, tied it off, and pounded away.  Came out very nice!  Gotta love gravity.
Tail riveted and bolted together.

Aft looking forward with the top skins removed

Everybody has to have one so here is another view from inside looking aft.

These are the clips I fabricated to hold the static lines as the pass over the bulkhead.

I plan on having a ventilation source for the back seats.  This is the drawing I used to cut the holes in each side of the tailcone.

And here it is after cutting the hole.  

Sunday, October 22, 2017

Finally riveting again

I probably shouldn't have said "finally" in the title because I have a lot of riveting ahead of me but I find that the riveting part is the most fun simply because its the final step of assembly for any part of the project.  This week I finished up the priming and have started riveting parts

A couple of the rear bulkheads in the tailcone.  You can see the tie down mount riveted to the bulkhead on the right.
Bulkhead frames riveted together

Riveting the J stringers to the bottom and sides.  I'm using a "back-riveting" technique and there is a 12x24" hunk of steel (from my table saw and not visible in this picture)  that I am using as the backing bar.  

Sunday, October 15, 2017

More tail-cone work

I've been doing a lot of work on the tail-cone lately.  not much for pictures but I did remember to take some when I was doing a little priming.  The area I created for priming in the basement is really working out quite well.

The down draft table with lots of tail-cone parts.

And more primed parts...and there are still lots more to be primed.

J channel stiffeners before priming.

After priming....

Longerons and the bottom of the tail-cone skin.  I decided to prime this skin because water does get into the tail cone and will pool there if the plane is left outside.

Sunday, October 1, 2017

Finally I got the right propeller

This week I finally got the correct propeller from Whirlwind.  I was very nervous that something else would go wrong since its been such an uphill battle with the front office at Whirlwind.  Not much has gone right in dealing with Whirlwind but I did finally get my propeller and it is beautiful.  Whirlwind was kind enough to paint my spinner as consolation gift for all of the errors that I have had to deal with over the past six months.  Starting with missed shipping dates (or incorrectly relayed to me), shipping the wrong prop, giving me a temporary prop to use while mine is being shipped, more missed shipping dates, and finally silence when I expressed my concern.  I had planned to buy a Whirlwind prop for the RV-10 but now I'm not so sure.  If I do it will be purchased WELL in advance of when I need it so they have lots of time to get me the correct prop.

Anyway, the new prop is installed and tested.  It works very well and maybe its just wishful thinking but if feels smoother than the demo prop I have been flying the past few months.  I flew it for about 40 minutes yesterday and was very happy with it.  No leaks of grease and no blade flex at all.

On the RV-10 I have made some progress this week as well.  I've finally finished up the elevators and trim tabs.  Next I'm off to the tail cone.  I contemplated waiting on the tail-cone because of the size of it but in the end I think I will just hang the completed tail-cone from the ceiling in the hangar when its done.  Maybe I can arrange it to look like an airplane crashed into the side of the hangar.  :-)

Leading edges of the right elevator completed.

Trim tab control cable mount riveted to the bottom of the access plate.

Access Plate sitting in the final install location

Elevator counterbalance inboard weight bolted in.

Outboard counterbalance weight bolted in.  If you look closely you will see some red liquid on the bolt threads...I used Loctite to make sure these nuts can't back out.  Just added insurance since these nuts are not accessible without drilling out the rivets and removing the fairings.
Finished Elevators with trim tabs attached.

The only thing I missed in this picture was the safety wire on the trim tab hinge pins.  That is now installed as well.

First step in working on the tail cone is to make this piece and tap the hole 3/8" threads.  This is where the tail tie down bolt will screw in.