Van's RV-9A in Aurora

The Big Picture

The Big Picture
Flying! 8/28/2011

Wednesday, June 29, 2011

2 hrs, 38 rivets
Tapped the last few holes to hold the empennage fairing on. Also riveted on the nutplate removed yesterday.
Drilled, deburred, dimpled, and installed nutplates for the right wing root fairing.

Tuesday, June 28, 2011

1.5 hrs
Drilled last remaining holes in empennage fairing and marked for final trimming.
Had to remove one nutplate on the HS, the fairing screw twisted off when removing it. Removing the nutplate was the fastest way to repair it.

Final attach of left wing with drift pins. Remove right wing.

Then helped Wayne with wiring.

Monday, June 27, 2011

2 hrs
Sanding, then coats of epoxy on fairing parts.

Sunday, June 26, 2011

5 hrs, 47 rivets
Started today with a visit from Jim Darrah and his Dad

Installed platenuts for left wing root fairing attach.
Rerouted pitot and AOA lines.
Installed pitot tube and heater controller. This was a pain.

Got in some time sanding on the fairings.

Ended the day with the Cub triplets lined up for a photo op. I love being at the airport.

Saturday, June 25, 2011

4 hrs

More sanding on fairings.
Drill last holes for empannage fairing attach (into longeron).
Remove left wing. Reroute pitot and static lines.
Drill, deburr, and dimple for wing root fairing nutplates.
Dimple wing root fairings.

Thursday, June 23, 2011

2 hrs
Finished rudder attach, including tightening the jam nuts and hooking up the rudder cables.
Also finished ELT antenna attach.
Working my way forward, now to finish the wing root fairings and permanently attach the wings.

Haven't taken photos for the past week or so, the camera was with Lynne in Santa Fe. But the camera is back in the shop now, so here are a couple of shots from Thursday night.

4 hrs
Attach VS, elevators, rudder to airframe.
Install ELT, ELT antenna, elevator pushrod, pitch servo wiring connector.
Will take some pictures soon.

Tuesday, June 21, 2011

2 hrs 58 rivets
Rivet nutplates for empennage fairing attach.

Monday, June 20, 2011

3 hrs
More sanding and epoxy on fairings. I counted about 25 separate pieces of fiberglass that go on the plane. They all take huge amounts of work.

Drill VS/HS and aft fuselage for #6 nutplates. Deburr and dimple.

Sunday, June 19, 2011

6 hrs
Sand fairings, apply more epoxy.
Drill empennage fairing and VS/HS to #27.
Fit and drill wing root fairing to #19.
Deburr wing root fairing.

Saturday, June 18, 2011

5 hrs
Sand empennage and elevator fairings. Apply another coat of epoxy.
Start sanding gear leg and intersection fairings for sealing. Also main wheel pants.

Attached wings to gauge wing root fairing fit, etc..

Friday, June 17, 2011

3hr, 4 rivets
Finish sanding spinner and rudder bottom cap.
rough sand elevator caps.
Apply layer of epoxy to elevator caps and empennage fairing.
Installed VAF data plate.

Thursday, June 16, 2011

3 hrs
Route and connect trim servo wires.
Drill out rivets on HS and aft fuselage for fairing attach.
Drilll empennage fairing to aft fuselage, VS, HS.

Spending more and more time at the hangar. It's like I'm cramming for finals or something, long hours with little food and sleep. Many thanks to Wayne for putting up with me!
2 hrs, 46 rivets
Another evening at the hangar.
We proved that the left tank is leak free. The balloon stayed inflated the same amount for two days. Yee Haw!
Riveted tank bracket nutplates. So the wings are ready to attach.
Riveted fairings to HS, VS, rudder cap.
Attached left elevator. Need to get the trim servo wiring hooked up.

Spent 3 hours Tuesday night priming various control surface fairings. HS, VS, spinner, etc.
In this heat, the K36 fast catalyst is not usable. It sets up in the gun and that makes it really hard to spray.

Another 2 hours Monday, marked and trimmed the empennage fairing Prepped various fairings for painting.

Sunday, June 12, 2011

7 hrs 32 rivets
Sand spinner for painting.
Fit rudder bottom cap. Drill and countersink for #6 screws, deburr, drill, dimple, and install nutplates.
Sand rudder bottom for painting.
Attach VS to fuselage. Install right Dynon.
Torque prop extension.

For Saturday, 5 hrs, 36 rivets
Workday at the airpark, so got a little bit of a late start.
Taking parts over to Waynes a few at a time.
Trim and fit right wing tip lense. Trim right wing tip.
Rivet nutplates to wing tips.
Trim and start sanding empennage fairing.

Wednesday, June 8, 2011

1 hr
Went over to Wayne's and we returned the trailer. So the main part of moving is over. Now to keep bringing something every time I come over.

Drilled the wingtips for the nav/strobe nutplates while dinner was cooking.

Helped Wayne install BNC connectors for his radios.

Then attached the HS to the fuse. Maybe for the last time!

Tuesday, June 7, 2011

3 hrs
Got the wings moved tonight. Many thanks to Wayne for his help moving, not to mention the use of his Tahoe. We used my Brother-in-Law's trailer.
We also brought over the HS, the flaps, the prop, cowling. All the big parts,
except the pushrod tubes.

Brought over one of the work benches and the wing cradle.

The ailerons, elevators, VS, and rudder will all fit in my car. Still working on fairings, but most of that doesn't need to be completely finished before being used. A couple more hours needed on the wingtips before they move over.

Didn't take any pictures. Doh!

Sunday, June 5, 2011

6 hrs, 4 rivets
Finished the cowling hing pin covers. Had to redo one of the nutplates installed yesterday, it just wasn't lining up right.

Did a first pass of sanding on the nose wheel fairing. I'll try to kick out a bit of fairing sanding every couple of days. I hate that task.

Started on the wing tips. Got the left side trimmed to fit, but not drilled yet. Started installing the left wing nav/strobe, a Pulsar NS from Aeroleds.
Trimmed and fit the plastic cover for the strobe installation. That was almost the last part of the kit that had not been touched.

Saturday, June 4, 2011

5 hrs, 12 rivets
I think the left tank is holding air. I added a bit of pressure last night, and it had a vacuum this morning. It's very sensitive to temperature. Today I put more pressure in, and it went up over the course of the day. It's back down below the original level now. If it goes back up the same point tomorrow then that's a take!

Installed the landing light for the left wing.

Started working on the cowl hinge pin safety/cover strips. Got one side done.
Also installed nutplates for the screws that join upper and lower cowlings behind the spinner. Countersunk, and these are ready to go.

Thursday, June 2, 2011

2 hrs
Started working on the left fuel tank. The inboard end of the left wing slid off the wing cradle a long time ago. It put a slight dent in the most inboard part of the leading edge, from where the tank rib is to the edge. I checked immediately and discovered a new leak, but waited till now to diagnose and resolve it.

It turned out to be simple. The dent pushed one of the rib tangs out very slightly, but enough to tear the proseal loose from the skin and cause a leak. The leak wsa confined to the immediate vicinity of this rib tang.

This likely means that the inside is not sealed super well in the area, although I'm not sure how that could be, I did use quite a bit of proseal. The dent doesn't go inboard from there.

To fix it, I sanded the area and cleaned it up with lacquer thinner. Then mixed up some proseal. Put some lacquer thinner in the bottom of the jar to thin it, and applied this slurry to the leak. Applied a little vaccuum and worked it around for while to try and feed some of the proseal into and through the leaky area. Then I applied gob of unthinned proseal to the area.

This definitely fixed the air leak, I hope it fixes the problem for good.

Moved the fuselage to the airport. Should be jumping for joy, but it was almost a disaster. I'll explain more when I'm not in shock. The plane arrived intact, that's what matters.

Wednesday, June 1, 2011

2 hrs, 16 rivets
Finish fitting nose gear intersection fairing. Installed all the nutplates, countersink the fairing for flush screws.

Yesterday used epoxy and flox to build up where the fairing screws are countersunk.

Fixing the left tank leak is up next.

Got the fuselage ready to move. Tomorrow will be Thursday.