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10-31-2016, 12:27 PM
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Join Date: Oct 2013
Location: Harare, Zimbabwe
Posts: 200
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Outboard Floor stiffeners and F-684 Gussets
IMG_0863 by Ed Fleming, on Flickr
To fit the outboard floor stiffeners I drilled them fore and aft first. Then I could use those two holes to hold them in position for match drilling to the skin.
IMG_0838 by Ed Fleming, on Flickr
Here is the successful left F-684 Gusset. These took some time to fit correctly and they are an edge distance minefield!! Firstly the bending is not really as shown on the plans. They need a bend right below where the firewall angle ends to fit properly. The other issue is that aft lower hole. It is critical in edge distance on two sides. You need to keep it as far forward as possible to make it easier to drill the forward edge to the firewall angle. This is also the hole that is critical on the aux longeron. I got all this right on the first one.
IMG_0836 by Ed Fleming, on Flickr
But then got this problem on the firewall angle. Don't lay out and drill the holes in the gusset until you mark where the firewall angle ends! This was my only replacement part in this section. Thank goodness I didn't drill the firewall!
__________________
Ed Fleming
RV-7- Nearly there!
Harare, Zimbabwe
Last edited by Z-EDD : 10-31-2017 at 03:21 AM.
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10-31-2016, 01:14 PM
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Join Date: Oct 2013
Location: Harare, Zimbabwe
Posts: 200
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F-7114 Gusset
I spent a long time researching this thing. It is not even mentioned in the instructions. Apparently Vans attitude is "fit it whenever you like" Since in the tailwheel planes it takes the place of the gear mounts, you could just drill it at the point where the instructions have the nose draggers fit the gear mount. However since it is held in place with 5 AN3 bolts, drilled through the lower skin, lower longeron and F-7101, I surmised that drilling it now was a good time as that would allow proper deburring of those big holes. I needed to adjust the outboard flange slightly to get a good fit.
IMG_0877 by Ed Fleming, on Flickr IMG_0877 by Ed Fleming, on Flickr
__________________
Ed Fleming
RV-7- Nearly there!
Harare, Zimbabwe
Last edited by Z-EDD : 10-31-2017 at 03:23 AM.
Reason: Fix photo links
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11-20-2016, 10:31 AM
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Join Date: Oct 2013
Location: Harare, Zimbabwe
Posts: 200
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F-724 edge distance
I had the typical edge distance issues on both ends of my F-623 Baggage bulkheads. The first 2 pictures show comparison shots of the outside of each conical bend and the relationship with the edge distance on the lower flange of the baggage bulkhead. The moral seems to be if you get the bend to fit nice and tight you'll get better edge distance. The next two photos show how I chose to resolve it with a new flange. This may not be necessary but I'm glad I took the time as this is a complex joint and this flange seems to reinforce and supports the corner of the conical bend. IMG_0845 by Ed Fleming, on Flickr IMG_0846 by Ed Fleming, on Flickr IMG_0914 by Ed Fleming, on Flickr IMG_0848 by Ed Fleming, on Flickr
__________________
Ed Fleming
RV-7- Nearly there!
Harare, Zimbabwe
Last edited by Z-EDD : 10-31-2017 at 03:25 AM.
Reason: Fix photo links
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11-20-2016, 10:39 AM
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Join Date: Oct 2013
Location: Harare, Zimbabwe
Posts: 200
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And the top....
On the upper flange I also had an issue on one side. This time I think I failed to ensure the rib was sitting tightly against the skin. I emailed Vans and apparently this is not an issue, so I left both sides at number 40 and will use a 3/32 flush rivet.
IMG_0919 by Ed Fleming, on Flickr
IMG_0919 by Ed Fleming, on Flickr
And now a gratuitous shot of the fully drilled fuselage before disassembly.
IMG_0917 by Ed Fleming, on Flickr
__________________
Ed Fleming
RV-7- Nearly there!
Harare, Zimbabwe
Last edited by Z-EDD : 10-31-2017 at 03:28 AM.
Reason: fix photo links
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11-20-2016, 11:06 AM
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Join Date: Oct 2013
Location: Harare, Zimbabwe
Posts: 200
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Disassembly and F-682D
And here we go with taking it all apart.
IMG_0884 by Ed Fleming, on Flickr
Did I say fully drilled? Not so fast! My vagrant (some would say jet setting) lifestyle of flying cargo planes full of rubber dog poop around the world, gives me plenty of time to contemplate and look ahead in the instructions, as well as other guys build logs. Thus I foresaw the problems with drilling the F-682D cover support angles and devised a way to get these drilled and riveted now. Basically these parts seem to be a bit of an after thought. The instructions have you drill them to the F-7101 webs after the skins are riveted on. There is barely a 1/8 gap between the F-7101 and the skin, so this drilling is tricky to say the least. Even after this setting the blind rivets is really difficult since they can't be fully inserted.
So I fabricated and drilled the F-782s to F-7101 with the skins removed. I did not drill the screw holes in the forward flange yet as the forward fuselage was disassembled so I wasn't completely sure these would be accurate.
IMG_0888 by Ed Fleming, on Flickr
IMG_0891 by Ed Fleming, on Flickr
IMG_0896 by Ed Fleming, on Flickr
This was a really tricky job even at this point, can't imagine what it would be like with the fuselage riveted! Had to reach up from the bottom with an angle drill
IMG_0892 by Ed Fleming, on Flickr
__________________
Ed Fleming
RV-7- Nearly there!
Harare, Zimbabwe
Last edited by Z-EDD : 10-31-2017 at 03:31 AM.
Reason: fix photo links
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11-20-2016, 12:06 PM
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Join Date: Oct 2013
Location: Harare, Zimbabwe
Posts: 200
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F-782D continued
I'll skip ahead to show how these came out. After prep and prime, and after the forward fuselage was reassembled but with the bottom skin still off, I match drilled the F-782As to the F-782Ds for number 8 screws. The F-7101s can then be removed, the F-782Ds riveted in place and the nut plates fitted. Then rivet F-7101 to F-902 as per the instructions and cleco the whole assembly back in place.
Note however that I riveted the nut plates first, thus forcing use of 2 blind rivets anyway! Silly, there should be easy access to rivet the nut plates after attaching to F-7101. You can also see where I messed up the position of the lower hole and had to use a single Lug nut plate.
IMG_0932 by Ed Fleming, on Flickr
IMG_0935 by Ed Fleming, on Flickr[url=https://flic.kr/p/ZWtsyj]
IMG_0937 by Ed Fleming, on Flickr
__________________
Ed Fleming
RV-7- Nearly there!
Harare, Zimbabwe
Last edited by Z-EDD : 10-31-2017 at 03:48 AM.
Reason: fix photo links
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11-25-2016, 01:07 PM
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Join Date: Oct 2013
Location: Harare, Zimbabwe
Posts: 200
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Prep and prime
One of the advantages of using a rattle can primer is that you don't need to build up a huge backlog of stuff to prime in one go. I like to do stuff in manageable chunks. These are all the stiffeners and bulkhead parts, prepped, dimpled/countersunk and primed in one day. Big part of the job done.
IMG_0921 by Ed Fleming, on Flickr
Here's how I dimpled the lower skin at the aft end of the centre section. A piece of scrap .040 drilled and dimpled serves as a shim. Then squeezed as normal.
IMG_0900 by Ed Fleming, on Flickr
When I built the F-705 I wasn't sure what I was going to do about painting the interior, so I did not prime it fully. I've now decided it will be easiest to prime and paint as much of the interior now, so I prepped, primed and painted the bulkhead. I'm using a locally available rattle can paint in a shade called "machinery grey"! Its not a world beating finish but should be easy to touch up as required.
IMG_0905 by Ed Fleming, on Flickr
I masked off non visible areas on the sides before painting. The bulkheads and stiffeners in the background are also waiting for paint.
IMG_0902 by Ed Fleming, on Flickr
__________________
Ed Fleming
RV-7- Nearly there!
Harare, Zimbabwe
Last edited by Z-EDD : 10-31-2017 at 03:59 AM.
Reason: fix photo links
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11-25-2016, 01:23 PM
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Join Date: Oct 2013
Location: Harare, Zimbabwe
Posts: 200
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Pitch servo mount and armrests
I purchased the Garmin Pitch servo mount and fitted it. This does not mean I am now committed to Garmin, as I understand the mounting hole pattern is common to most servos. When I opened the bag I couldn't see any instructions and was stumped for a while before I eventually looked in the G3X installation manual I had downloaded. Sure enough, the instructions are there under GSA28 servo installation. quite straight forward.
IMG_0871 by Ed Fleming, on Flickr
IMG_0872 by Ed Fleming, on Flickr
The armrests are quite flimsy and most people seem to reinforce them. This seems sensible and I am quite sure I will have plenty of .063 angle left over. I filed it until it nested nicely, trimmed the long edge flush and match drilled for 3/32 flush rivets.
IMG_0906 by Ed Fleming, on Flickr
IMG_0907 by Ed Fleming, on Flickr IMG_0908 by Ed Fleming, on Flickr
__________________
Ed Fleming
RV-7- Nearly there!
Harare, Zimbabwe
Last edited by Z-EDD : 10-31-2017 at 03:52 AM.
Reason: fix photo links
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11-26-2016, 09:52 AM
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Join Date: Oct 2013
Location: Harare, Zimbabwe
Posts: 200
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Painting armrests
I found this gorgeous shade of blue rattle can paint. I like it so much I may just match it for my exterior trim. In the meantime I decided to try painting the armrests with it to see how it looked against the grey. I like!
IMG_0909 by Ed Fleming, on Flickr
The armrests top off a massive pile of primed or painted parts waiting for reassembly
IMG_0923 by Ed Fleming, on Flickr
But first there are a couple of riveting tasks. I made sure all nut plates were fitted as required. Some will be very hard to do later. Also the F-704H side plates are riveted to the skin. I also did the upper 2 rivets, not specified but I could see no reason not to do them now. I also set a solid rivet in the aft lower hole. A blind rivet is called out but I could not see why. The forward hole needs one because it also attaches the lower skin so cannot be done now.
IMG_0926 by Ed Fleming, on Flickr
The F-684 is riveted to the firewall angle. This view shows the complex bend quite well.
IMG_0924 by Ed Fleming, on Flickr
__________________
Ed Fleming
RV-7- Nearly there!
Harare, Zimbabwe
Last edited by Z-EDD : 10-31-2017 at 03:42 AM.
Reason: fix photo links
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11-26-2016, 10:01 AM
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Join Date: Oct 2013
Location: Harare, Zimbabwe
Posts: 200
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Reassembly
Its finally time to put it all back together.
IMG_0927 by Ed Fleming, on Flickr
IMG_0929 by Ed Fleming, on Flickr
IMG_0930 by Ed Fleming, on Flickr
And now ready for firewall sealant.
IMG_0939 by Ed Fleming, on Flickr
__________________
Ed Fleming
RV-7- Nearly there!
Harare, Zimbabwe
Last edited by Z-EDD : 10-31-2017 at 03:45 AM.
Reason: fix photo links
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