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02-24-2016, 04:50 AM
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Join Date: Jan 2015
Location: Jamestown,NY
Posts: 631
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I just finished my stall warning cover and was not happy with the fit either. Hadn't even considered making my own cover until I saw yours. Now I have to do it!!!! Thanks for the pic!!
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03-17-2016, 01:28 PM
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Join Date: Oct 2013
Location: Harare, Zimbabwe
Posts: 200
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Flap braces
Moving on to the flap braces, these were a bit trickier than I thought. The problem is the flange which rivets to the rear spar is straight, but the section which attaches where the rear spar is doubled should be higher. hopefully you can see what I mean from the pictures. When you first cleco it in place this puts quite a kink in the lower flange where it rivets to the bottom skin. This required quite a bit of adjusting to get things straight. I got it to a point where it was straight with the skin clecoed on, but I found out later I needed to get it straight without the skin to help. Thats because when you drill the hinge you can't use clecos.
IMG_0897 by Ed Fleming, on Flickr
IMG_0898 by Ed Fleming, on Flickr
To do the countersinks in the lower flange I match drilled it to a piece of wood to guide the pilot.
IMG_0900 by Ed Fleming, on Flickr
__________________
Ed Fleming
RV-7- Nearly there!
Harare, Zimbabwe
Last edited by Z-EDD : 10-24-2017 at 03:27 PM.
Reason: Fix photo links
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03-19-2016, 01:50 AM
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Join Date: Oct 2013
Location: Harare, Zimbabwe
Posts: 200
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Quote:
Originally Posted by dwranda
I just finished my stall warning cover and was not happy with the fit either. Hadn't even considered making my own cover until I saw yours. Now I have to do it!!!! Thanks for the pic!!
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Glad to be of help! Actually although these little diversions eat up time I find them very enjoyable and the results usually satisfying.
__________________
Ed Fleming
RV-7- Nearly there!
Harare, Zimbabwe
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03-19-2016, 02:16 AM
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Join Date: Oct 2013
Location: Harare, Zimbabwe
Posts: 200
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Aileron mounts and gap seal
Moving on to the Aileron mounts. I primed the inner surfaces first before riveting them together and drilling to the wings. later I primed the outer surfaces. Only slight challenge here was some of the bearings were binding and I had to relieve the recesses a little. This is not apparent with the parts just clecoed together so I used C-clamps to put more pressure over the rivet holes and made adjustments until the binding stopped. Sorry no pictures of that particular process!
IMG_0863 by Ed Fleming, on Flickr
IMG_0879 by Ed Fleming, on Flickr
IMG_0879 by Ed Fleming, on Flickr
Don't forget that some of these rivets need to be countersunk!
Next up the gap seal. Minor issue here, there was some slight interference between the gap seal and one of the mounts so its a good plan to have them all clecoed on to fix something like this before priming.
IMG_0862 by Ed Fleming, on Flickr
Vinyl peeling is always a favourite job for smaller builders![url=http://s560.photobucket.com/user/edfleming/media/RV-7%20Build/IMG_0883.jpg.html]
IMG_0883 by Ed Fleming, on Flickr IMG_0883 by Ed Fleming, on Flickr
__________________
Ed Fleming
RV-7- Nearly there!
Harare, Zimbabwe
Last edited by Z-EDD : 10-24-2017 at 03:30 PM.
Reason: fixing photo links
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03-19-2016, 03:15 AM
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Join Date: Oct 2013
Location: Harare, Zimbabwe
Posts: 200
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Ailerons
Meanwhile I was working on the ailerons. After the familiar stiffener prep and riveting came the dreaded trailing edge bend. Now, when I did this on the elevators it did not go very well. Largely because I did not follow the instructions closely enough! When making my bending brake I did not have any sturdy 2x4s handy so decided to use some block board that I had laying around. I surmised that if I put enough hinges along the join it would hold up. Well it did not! The sheet wood just flexed under the strain and I ended up with an uneven bend that took a few hours to fix. Here are some pictures of the offending device-
IMG_0400 by Ed Fleming, on Flickr
IMG_0400 by Ed Fleming, on Flickr
So for the ailerons I wised up and went back to basics. I used sturdy wood that was left over from the wing stands and built more or less as per the instructions with the minor change in orientation as seen in George Orndorffs video. It worked a treat! Nice even bends with the correct radius. I didn't even use a piece of dowel inside the radius, it isn't needed. Just go for it as George does and its really simple. I did just one thing wrong. I made this brake just wide enough for the ailerons. But the flap skins could also do with a little extra bending so if I could do this again I'd make it wide enough for the flaps as well
IMG_0843 by Ed Fleming, on Flickr IMG_0843 by Ed Fleming, on Flickr
__________________
Ed Fleming
RV-7- Nearly there!
Harare, Zimbabwe
Last edited by Z-EDD : 10-24-2017 at 03:34 PM.
Reason: fixing photo links
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03-19-2016, 03:33 AM
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Join Date: Oct 2013
Location: Harare, Zimbabwe
Posts: 200
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More Ailerons
__________________
Ed Fleming
RV-7- Nearly there!
Harare, Zimbabwe
Last edited by Z-EDD : 10-24-2017 at 03:37 PM.
Reason: Fix photo links
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03-19-2016, 03:55 AM
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Join Date: Oct 2013
Location: Harare, Zimbabwe
Posts: 200
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Closing the ailerons
The only slight problems I had closing the ailerons were with the CS4-4 blind rivets. As you can see from the photo below I had a couple of the mandrels snap off way too high. I never really got to the bottom of this but switching to a different (cheap, locally bought  ) puller actually solved it and I had no more issues. Per the vans advice in section 5, these 2 were just cut off and ground flush. The other problem you can see in this photo is that the flush heads were being distorted during the pulling process. This was due to the hole on the bottom of the puller being too large. I actually could not find a hole of the correct size on either of my 2 pullers (one came with my tool kit from Cleaveland  ) so ended up fabricating a spacer from .032 with the correct size hole drilled using my number size drill bit set. This worked a treat and the remaining rivets were fine.
IMG_0857 by Ed Fleming, on Flickr IMG_0857 by Ed Fleming, on Flickr
__________________
Ed Fleming
RV-7- Nearly there!
Harare, Zimbabwe
Last edited by Z-EDD : 10-24-2017 at 03:38 PM.
Reason: Fixing photo links
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03-19-2016, 04:35 AM
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Join Date: Oct 2013
Location: Harare, Zimbabwe
Posts: 200
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Flaps
A common problem with the flaps is this gap between the aft flange of the ribs and the "rear spar" bent into the bottom skin. The instructions say that shims are acceptable but I felt there must be a slightly better way. I found it easy to adjust the flanges outward slightly as pictured below. Just another possibility.
IMG_0889 by Ed Fleming, on Flickr
IMG_0890 by Ed Fleming, on Flickr
IMG_0891 by Ed Fleming, on Flickr
It now fits much better but the friction of the flange against the rear spar can cause the bottom skin to sit away from the rib flange as in the picture below. If I had drilled it like this I would have felt really dumb but luckily I caught it!
IMG_0892 by Ed Fleming, on Flickr
Fabricating the two FL-706As. Pilot holes being drilled. Why do it twice
IMG_0893 by Ed Fleming, on Flickr
This is how I bent the FL-706Bs. Hard to see but the forward end is held securely in the vice and the wood blocks clamped on gave me the leverage to easily make the bend. Easy peasy.
IMG_0894 by Ed Fleming, on Flickr
__________________
Ed Fleming
RV-7- Nearly there!
Harare, Zimbabwe
Last edited by Z-EDD : 10-24-2017 at 03:42 PM.
Reason: fixing photo links
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03-19-2016, 05:04 AM
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Join Date: Oct 2013
Location: Harare, Zimbabwe
Posts: 200
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Flaps continued
The next slightly tricky part of the flaps is drilling the hinge. This would be trivial if it weren't for the fact that research showed many builders have edge distance problems down the road when drilling the flaps to the wings. Fore warned is fore-armed so I decided not to drill these exactly on the centre line, but rather gave myself just a couple of 32nds extra to work with. See in a couple of posts how this worked out.
IMG_0885 by Ed Fleming, on Flickr IMG_0885 by Ed Fleming, on Flickr IMG_0885 by Ed Fleming, on Flickr IMG_0885 by Ed Fleming, on Flickr
__________________
Ed Fleming
RV-7- Nearly there!
Harare, Zimbabwe
Last edited by Z-EDD : 10-24-2017 at 03:46 PM.
Reason: Fix photo links
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03-19-2016, 06:33 AM
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Join Date: Oct 2013
Location: Harare, Zimbabwe
Posts: 200
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Riveting the flaps
IMG_0198 by Ed Fleming, on Flickr
A piece of weather strip along the rear spar allowed me to rest the bucking bar on it. Easy to just hold it in place while riveting.
IMG_0208 by Ed Fleming, on Flickr
I weighted the flap down to a flat piece of board when riveting the ribs to the top skin.
IMG_0645 by Ed Fleming, on Flickr
__________________
Ed Fleming
RV-7- Nearly there!
Harare, Zimbabwe
Last edited by Z-EDD : 10-24-2017 at 03:48 PM.
Reason: Fix photo links
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