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  #1  
Old 11-08-2013, 02:25 PM
akarmy's Avatar
akarmy akarmy is offline
 
Join Date: Jan 2005
Location: Auburn, WA
Posts: 677
Smile RV-8 Andy Karmy - N898TT

Initial design specs for my RV-8 are to keep it simple include the following:
  • RV-8 slow build kit
  • Aerosport 0-360-A2A with Superior Roller Lifters
  • Dual P-Mag electronic ignitions - EI Commander to monitor them
  • Catto 3 blade composite prop - 68x76 Gen2 with Nickel edges
  • Dynon Skyview 10" with ADS-B & Transponder
  • Garmin GTR200 with integrated intercom
  • Aeroelectric style fuse based electrical system
  • AeroLED strobe & position lights
  • AeroLED Aerosun VX wingtip taxi & landing lights
  • Grove airfoiled aluminum gear
  • Oregon Aero seats
  • Crow seat belts with rotary buckle
  • DJM two lever throttle quadrant
  • JDair tailwheel & steering link
  • Skybolt cowl fasteners
  • and many more decisions I have not yet uncovered

History:
This will be my 4th homebuilt. Starting with a miniMAX ultralight, then a RV-9A, Currently flying a Kitfox 7, and now building a RV-8. Over the 700 hours I flew the RV-9A i learned a few things about what I wanted. I flew formation with it, got interested in aerobatics, and flew alone quite a bit. All that lead me back to the RV-8 as a better match to my needs. We will see how that works out, but it sure seems like fun from where I sit.
Building:
I'm building in my attached 2 car garage at home. So much easier to work on it every day not having to drive to the airport. I'm using about half of the garage at this point and should be able to keep it contained in that for the most part. I'm lucky I can move parts to the hangar as they are finished to keep some room to move around.
Turns out, I'm using most of the entire garage at this point and even had to take a trailer load of woodworking tools out to the hangar to make room! Seems you can never have too much room while building.

Links:
So, on with the show, let's get building.
__________________
Andy Karmy
Covington WA

RV-8 - Flying!
RV-9A - sold

Dec 2020 Paid

Last edited by akarmy : 03-11-2014 at 11:13 AM. Reason: minor edits
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  #2  
Old 11-08-2013, 02:39 PM
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akarmy akarmy is offline
 
Join Date: Jan 2005
Location: Auburn, WA
Posts: 677
Default Tail Kit

This is where it always starts, at least for those of us lucky enough to drive to Vans to pickup our parts.




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Andy Karmy
Covington WA

RV-8 - Flying!
RV-9A - sold

Dec 2020 Paid
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  #3  
Old 11-08-2013, 02:44 PM
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akarmy akarmy is offline
 
Join Date: Jan 2005
Location: Auburn, WA
Posts: 677
Default Tail continued




Following some posts on making the brake, I used 2x6 lumber and used it on edge which made it much easier to get the leverage on it for the bend. I also added a 3ft clamp to the 2x6 to help pull it down.



Ah yes the dreaded trim tab bending. Also lot's of good ideas and advice on this topic if you just search for it. I really just followed the plans and bent the tabs using some oak forms and double sided carpet tape. I used the rivet gun and flat set to finish it off.

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Andy Karmy
Covington WA

RV-8 - Flying!
RV-9A - sold

Dec 2020 Paid
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  #4  
Old 11-08-2013, 02:50 PM
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akarmy akarmy is offline
 
Join Date: Jan 2005
Location: Auburn, WA
Posts: 677
Default Tools

The DRDT turned skin dimpling into a quiet peaceful, almost fun activity. Sure is heavy!



Why did no one tell me about this amazing tool during my RV-9A build? So much easier! Highly recommended.



This is my back rivet plate that I built during the RV-9A construction. It's 1/4" plate I got at the metal shop and made the holder to surround it. Just make sure you stay between the lines and you are good to go. Took a lot of belt sanding to polish it up nice and smooth initially.



My new best friend, the tungsten bucking bar. Small and heavy, just what is needed in a number of situations.

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Andy Karmy
Covington WA

RV-8 - Flying!
RV-9A - sold

Dec 2020 Paid
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  #5  
Old 11-08-2013, 02:56 PM
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akarmy akarmy is offline
 
Join Date: Jan 2005
Location: Auburn, WA
Posts: 677
Default Wings

How do you transport the wing kit home in your Volvo station wagon? With your trailer and some creative strapping. I think the Vans guys much cringe with all the creative pickup solutions that show up outside their back door. This worked out great and was very solid for the trip home up the freeway.



First you need to do the inventory, best if you can get some help!




Lots of fluting to do as you get parts ready.

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Andy Karmy
Covington WA

RV-8 - Flying!
RV-9A - sold

Dec 2020 Paid
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  #6  
Old 11-08-2013, 03:08 PM
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akarmy akarmy is offline
 
Join Date: Jan 2005
Location: Auburn, WA
Posts: 677
Default Wings continued

Wings are in the jigs, building two of them in parallel with about 4 ft between the posts. This has worked out great and gives just the right amount of working space as you rivet the top skins on.



Nose D-section going on. The only think challenging is getting them riveted to the spar! Some have used pop rivets, but we stuck it out with the gun and some creative language.



Some proof I was at least in the general area of the parts being put together.



Safe-Air pitot mast fit into the skin. This was fairly easy to get in place using the provided templates to cut the skin hole.

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Andy Karmy
Covington WA

RV-8 - Flying!
RV-9A - sold

Dec 2020 Paid
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  #7  
Old 11-08-2013, 03:50 PM
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Don Patrick Don Patrick is offline
 
Join Date: Feb 2010
Location: GTA, Ontario
Posts: 873
Default Wow!

That's a lot of work in one day Andy!!!

Looking good!

Don
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  #8  
Old 11-08-2013, 03:53 PM
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akarmy akarmy is offline
 
Join Date: Jan 2005
Location: Auburn, WA
Posts: 677
Default Z-Brackets

Using the Hurlbut memorial method, as documented by lots of other people (like Brad Oliver's rv-7 factory site), I attacked the z-brackets for the tanks. This is a great method which easily allows for a perfect alignment of the tanks and easy install later on.




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Andy Karmy
Covington WA

RV-8 - Flying!
RV-9A - sold

Dec 2020 Paid

Last edited by akarmy : 11-12-2013 at 02:04 PM.
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  #9  
Old 11-08-2013, 04:30 PM
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akarmy akarmy is offline
 
Join Date: Jan 2005
Location: Auburn, WA
Posts: 677
Default Fuel Tanks

On to the tanks. They start out with the z-bracket alignment and parts going onto the spar (as you know)



Then, out comes the Proseal. YEA. Now we are having fun.




Using the Rick Galati method is sure a timesaver and much cleaner also.

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Andy Karmy
Covington WA

RV-8 - Flying!
RV-9A - sold

Dec 2020 Paid
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  #10  
Old 11-08-2013, 04:38 PM
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akarmy akarmy is offline
 
Join Date: Jan 2005
Location: Auburn, WA
Posts: 677
Default Leaking Tank Baffle

So the sad news was one tank had major problems with the rear baffle seal. It seems that I didn't get the line of sealant close enough to the rivet line and it sagged before i got the baffle in place, leaving literally clear space between the baffle and the skin. So after reviewing the archives, I dove in and opened up the tank and fixed it! The other tank sealed just fine by putting the pro seal line touching the rivet line and using a bit more (thicker bead).





These are the Vans "fuel tank repair" covers. Already cut and punched.

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Andy Karmy
Covington WA

RV-8 - Flying!
RV-9A - sold

Dec 2020 Paid
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