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RV-7A #73840

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RossK

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Well, I've started building an RV-7A
I'm the third owner of this Kit and if you haven't read Vans warnings about buying older kits, particulary the bit about unboxed, original packaging you should.
Kit 1.jpg
When I unboxed the kit for the first time in its 14 year life, this is the result of storing aluminum in carboard for 14 years
Both HS-609PP pieces have corrosion like this20240321_191749.jpg

So, 2 new HS-609PP's are on order, and I moved on to the Vertical Stabiliser

20240321_193147.jpg20240321_210331.jpg
 
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Hi Ross,

Welcome to the world of building an RV-7A. It is a very interesting journey and very satisfying as you see it come together. Plus you will get to meet some interesting people along the way and learn some new skills.

If you haven't already done so I would suggest you join your local SAAA Chapter so you have a group of fellow builders to interact with and who can provide advice and help. Plus that Chapter will have its own Technical Councillor to work with you through the build process.

Good luck and have fun.

Regards,
 
There will be plenty of bumps in the road along the way. The end result is worth it.

You may have already done so, but I recommend you review the service bulletins related to the empennage that have been released since that kit was made 14 years ago. It's a much simpler process to include the new & improved parts into the tail when you're at this stage.
 
I've joined the SAAA, yet to get to a meeting though.
I've transferred the Kit # with Vans to me, and have received the empennage SB kits required for a 14yo kit.
Interestingly, Vans wouldn't release the SB kit order until I had a kit # registered to me.
 
RossK said:
Well, I've officially started building an RV-7A
I'm the third owner of this Kit and if you haven't read Vans warnings about buying older kits, particulary the bit about unboxed, original packaging you should.

When I unboxed the kit for the first time in its 14 year life, this is the result of storing aluminum in carboard for 14 years
Both HS-609PP pieces have corrosion like thisView attachment 58925
Click to expand...
The good news is that those parts above did that mostly because they're made from bar stock thats not alclad. The plans will tell you for sure, but a rule of thumb is that any bar or angle stock MUST be primed/painted for this very reason. The parts that are covered in blue vinyl are alclad (the core alloy is covered with a top layer of pure aluminum). The blue stuff can entrap moisture, especially around the edges and street some corrosion going, but overall they will fair much better than what you've got going on above.
 
Finally making progress after waiting for tools to arrive.
Yes, there are some dents in my skins:(
Yes, i've learnt how to drill out poorly set rivets.
I'm sure there will be more of both in my future.
Vertical Stab and RH Horizontal done.
LH Horizontal looks like fun, having to work with a 2.5m piece :unsure:.
 

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LH side of the HS going together well, no issue apart from its length - I think I need a bigger work bench for when the wing kit arrives.
 

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Elevators Done.
How nice is backrivetting :) !

Now to fit and balance them.

Wing Kit should arrive here in Aus late July.20240523_221036.jpg20240602_213432.jpg20240602_213446.jpg
 
Well, after a bit of a forced break due to shipping delays, I'm back at it!
Wing kit arrived, finally.
2 nights to inventory, and put it all away - it's surprising how little space it actually takes up.
Although, I'm sure it'll take up more space when it's assembled :)
 

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Small milestone today.
This turned up.
O-360 A1AD with 170hours SMOH, 2 years ago. Came with Starter, alternator and governor.
It's been run, pickled, fogged, sealed and dessicant plugs installed my my LAME (A&P)
,20241011_104418.jpg
Way too early, but it was a good deal.
Plan is to put full FI and EI on it (SDS).
It can sit in it's sealed bag until I'm ready for it now.
 
Niiiiiice. Very good progress. I like that you've labeled "top" on the spar. While it seems obvious to some, labeling top, bottom, left, right, underside, etc. will help prevent many, many errors down the road. A Sharpie is your friend. Or at least that's what we call markers on this side of the world. You may use another brand down under.
 
D-Dubya said:
Niiiiiice. Very good progress. I like that you've labeled "top" on the spar. While it seems obvious to some, labeling top, bottom, left, right, underside, etc. will help prevent many, many errors down the road. A Sharpie is your friend. Or at least that's what we call markers on this side of the world. You may use another brand down under.
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Thanks, sharpie seems good worldwide. I have a few of them floating around the workshop.
Also written on the front face, "Up" and "outboard" with corresponding arrows, just for good measure 😁
 
These things are fiddly and time consuming after some delays (personal) the right hand tank is done for now. Just waiting to leak test it 🤞
Pic of the completed tank, and the innards - pickup, vent and return line.
20241217_230807.jpg20241209_211948.jpg
 
Just a minor observation.
Be careful tightening the fitting on the return line. It can rotate and there's nothing to hold on the outside while you torque it.
 
Progess has slowed - life gets in the way.
My daughter bought a house that needed a full renovation. But were almost done with that.
RH Wing done with flap and aileron fitted. Left wing on the stand.

Kitchen photos, before and nearly done.
 

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If you had left all those cabinets out and hadn't installed an oven, you'd have room to build the fuselage in there! 😁
 
D-Dubya said:
If you had left all those cabinets out and hadn't installed an oven, you'd have room to build the fuselage in there! 😁
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If I had left all those cabinets out and hadn't installed an oven, I would be building the fuse by now 🙄
Every wall, ceiling and cornice had to be stripped and repainted, multiple holes in walls repaired, wardrobes rebuilt, lights rewired, floor coverings removed and floating floor installed!
Takes 30 seconds to type, but 5 months to do it.
The things we do for our kids :)
 
And.......
Left Tank is done. The balloon's been on there 48hrs now ( I fitted the tank to the spar after 24hrs ), so I'm calling it good.
20250831_171510.jpg
Top and bottom skins are deburred and dimpled ready to rivet.
Still have to run the wires for wingtip lights and pitot lines.
 
Bottom wing skins going on.
The little things always take more time than you think - Pitot and AOA tubes, Magnetometer wiring, fitting temp sensor, flap brace and aileron fairing etc.
20250915_225618.jpg
Used a Jedi mind trick and my wife suggested storing the finished parts in the spare bedroom so I have space to start the fueselage ;).
 
Consider making the wire holes/grommets a bit bigger than you think you need if it’s not too late.
 
Another milestone reached.
Fuselage Kit arrives home, now to find space to put it all, I wonder if that other bedroom is free?
20251119_182323.jpg
 
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RossK said:
Another milestone reached.
Fuselage Kit arrives home, now to find space to put it all, I wonder if that other bedroom is free?
Click to expand...
No worries. It's mostly paper!
You're serial is not far from mine. 73391. I flew not long ago.
 
Joined the centre fuse section to the tailcone. It actually went better/easier than I expected. Which was a relief.
Fitted the RH F770 Side skin and all looks ok, longeron bend matches the side skin perferctly. So I called it a night and will tackle the LH skin tonight.
20260319_215641.jpg 20260319_214536.jpg
 
I'm pretty sure I've read every thread on VAF regarding the Conical Bend. So many possiblities to stuff this up and being in Australia, a very expensive stuff up it would be.
Followed all the advice, filed, deburred, polished and fitted the angles and did it, not quite one motion, but sort of three quarters, and then a last effort to get the 90deg forward end right.
What a relief, no cracks.
Refitted the skin and called it a night, will tackle the left one tomorrow.
20260323_213519.jpg
 
LH F-770 Concical bend done! :D
Thanks to VAF and all the RV'ers who have posted techniques on how to do this. I'm sure I would have stuffed it up just following the manual.
2 replacement skins and freight to Australia, US$380+Freight
VAF Patronage - Priceless.

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Firewall drilled last night.
I fitted it the previous day, but the longerons needed more twist as the W602's were not fitting the longerons very well.
So pulled it apart, removed the F772 bottom skin, removed the F770 to longeron clecos and 'tweaked" the longerons a bit more. Refitted the clecos, refitted the firewall and refitted the F772 bottom skin and rechecked. Nope :cautious: .
Repeated all of the above and voila, the W602's fit neatly in to the longerons.
So clamped it all and went to town with the drill 😁. Gotta love drilling all those holes in the stainless steel.
I'm starting to get very low on clecos.....

20260330_224136.jpg
 
Good progress! I'm slightly ahead of you on a 9 build. A lot of drilling and countersinking on those longerons.
 
I've been working on the forward fuselage section, lots of small fiddly stuff going on up here!
It's getting harder to convince my wife that I'm actually doing stuff, she can't tell the difference :ROFLMAO:
Got the Rudder pedals fitted with 3 spots drilled for adjustment. Picture has them in the most rear position.
20260416_205944.jpg

Next, forward skin goes back on so the F772 floor stiffeners can go in.
 
RossK said:
I've been working on the forward fuselage section, lots of small fiddly stuff going on up here!
It's getting harder to convince my wife that I'm actually doing stuff, she can't tell the difference :ROFLMAO:
Got the Rudder pedals fitted with 3 spots drilled for adjustment. Picture has them in the most rear position.
View attachment 115315

Next, forward skin goes back on so the F772 floor stiffeners can go in.
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Move them to the forward position. I have a 30" inseam. Short. I thought aft would be perfect. Way too far back. Forward is perfect. Doesn't work for anyone else, but it's my airplane!
 
wirejock said:
Move them to the forward position. I have a 30" inseam. Short. I thought aft would be perfect. Way too far back. Forward is perfect. Doesn't work for anyone else, but it's my airplane!
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Yes, thanks Larry, my plan is to final install them at the most forward position. This was just for fitting the 3 different positions, the last one drilled was the most rear position, so I took a photo with the satisfaction of another small job done.
Brake pedals were dropped off at the anodizers today - need to match your fancy ones 😁
 
RossK said:
I've been working on the forward fuselage section, lots of small fiddly stuff going on up here!
It's getting harder to convince my wife that I'm actually doing stuff, she can't tell the difference :ROFLMAO:
Got the Rudder pedals fitted with 3 spots drilled for adjustment. Picture has them in the most rear position.
View attachment 115315

Next, forward skin goes back on so the F772 floor stiffeners can go in.
Click to expand...
Wait till you get to the wiring. Months of what looks like no progress.
 
RossK said:
I've been working on the forward fuselage section, lots of small fiddly stuff going on up here!
It's getting harder to convince my wife that I'm actually doing stuff, she can't tell the difference :ROFLMAO:
Click to expand...
It's like building a house. You can have the big chunks done and it looking like a house relatively quickly. It's all the stuff that comes after that takes forever.
 
Mini Update - so the fuse is disassembled and I've been deburring, dimpling and countersinking, and countersinking, and countersinking, and countersinking..............those Longerons :eek:

So, some parts came back from the anodisers, so I put the drill down and picked up the squeezer, so nice to actually build something.

Pedals - inspired by wirejock, thanks Larry 😁.
20260506_202141.jpg
 
RossK said:
Mini Update - so the fuse is disassembled and I've been deburring, dimpling and countersinking, and countersinking, and countersinking, and countersinking..............those Longerons :eek:

So, some parts came back from the anodisers, so I put the drill down and picked up the squeezer, so nice to actually build something.

Pedals - inspired by wirejock, thanks Larry 😁.
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Wow! Those really look great.
 
So the fuselage came apart and the long process of deburing, dimpling, countersinking and painting parts started.
20260430_220556.jpg

Last weekend, it started going back together, the centre section was rejoined to the tail and side skins were refitted
.20260521_221858.jpg
Then the rivetting started, it's now one piece, permanently.
Belly skin rivets done (keen eyes will find the one rivet that got drilled out)
20260526_212904.jpg
Longerons riveted to the skins and F704
20260526_212915.jpg
 
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