Getting ready to start RV-7 Slow build wings. Need input

[Draker]

Just finished my wings (minus the wingtips). Trying to recall all my mishaps and pitfalls. Some things I can think of:

1. Basic workmanship. Measure twice before you drill still just as important as when doing the empennage, otherwise you'll end up with this:



...or this:



2. Be extra careful whenever you drill, rivet, touch, or look at the main spars, otherwise you'll end up with this:



3. Take your time with the pro-seal and don't worry about using too much. Too much is better than too little. Luckily I had no leaks around rivets, but I neglected to coat all the electrical connections to the capacitive fuel sender plates, and I ended up with small leaks through these wires, through the BNC connectors!



4. Be careful when deburring the large sheet metal skins. Don't use a grinder wheel:



5. Think about how you'll run the pitot lines through the bellcrank area. I ended up using a bracket like some other builders have done. This was after trying about three different designs:



6. Not sure what advice to give to end up with a straight aileron. I did everything according to the plans and still ended up with about 1/4 inch of twist on each:



Keep the work surface flatter than leveler than I did?

7. Deburring/smoothing out the inside of the aileron counterweight tubes after drilling. I wrapped some sand paper onto the end of a dowel and used that:



Used a similar tool to smooth out the inside of the bellcrank parts so the bolts fit through.

8. If you're going to go with the duckworks leading edge landing lights, cut those holes before riveting the leading edge to the spar. They make it easier to reach a few of the rib-to-spar rivets. I posted a write-up on my experiences riveting the leading edge ribs here: http://www.vansairforce.com/communit...d.php?t=156528

[jcarne]

If you install the stall warner mount it before you install the leading edge on the wing. I still don't know how the heck I'm going to get that one done...

[gvouga]

I wish I had closed off the area under one wing walk to use as a smoke oil tank. I've seen others do this and it holds ~ 8 gal. It's SO much nicer and cleaner (safer?) to have smoke oil outside of the cockpit.

To take it a bit further, I would also seal the outer leading edge to allow the full leading edge to hold fuel. 95% of the time I never near this, but there are some times that it would be nice to have. It doesn't add much extra weight (empty) and would be there when I wanted to use it. I realize this is not for everyone, but since you asked...

[flyabq]

Originally Posted by gvouga

I wish I had closed off the area under one wing walk to use as a smoke oil tank. I've seen others do this and it holds ~ 8 gal. It's SO much nicer and cleaner (safer?) to have smoke oil outside of the cockpit.

To take it a bit further, I would also seal the outer leading edge to allow the full leading edge to hold fuel. 95% of the time I never near this, but there are some times that it would be nice to have. It doesn't add much extra weight (empty) and would be there when I wanted to use it. I realize this is not for everyone, but since you asked...

So would you then install a smoke pump in that bay?Also how much of the plumbing? I am not doing smoke to start with, however I Love the idea down the road.

[gvouga]

Originally Posted by flyabq

So would you then install a smoke pump in that bay?Also how much of the plumbing? I am not doing smoke to start with, however I Love the idea down the road.

Sorry for the slow response... Oshkosh required my presence.

No, I would not install the smoke pump in the bay. I would probably put the pump on the firewall, but I really haven't given that part much thought. I just know that I have a tank in my baggage compartment now and it's a pain to fill and messy.

If you think you want smoke down the road then I would definitely seal off the area under the wing walk, add a flange for a fuel cap, add AN fittings in the wing root, and add a vent line. This should add minimal weight (when empty) and would be easy to complete the plumbing later without major effort. You could also use the tank for a few extra gallons of fuel instead of smoke oil if you decided not to go the smoke route.