Posts Tagged ‘drill’

Still prepping fuse parts

August 29, 2011


For your viewing pleasure here’s the boys enjoying the Blues over Lake Washington earlier this month. As for the project, i’ve been working on it I swear. It’s really just a 1000 little tasks without much visual payoff so I’ll spare you the pics of pretty countersunk holes in a neat little row.

I’m still slowly working through all the final steps before starting the riveting on the main fuse. I’m excited to see if I got a the puzzle pieces made correctly! All the deburring, dimpling, and countersinking including the longerons is done on the internal structures. I’ve primed about 2/3 of these parts. The left forward fuse pieces still need to be etched and primed. The skins still need to be prepped but that should be kinda fun as imam trying to “eat my vegetables”‘first. Also, I have to go back and find a solution for one hole I doubled drilled on a bulkhead. After that I’ll be reassembling the canoe! Work is going to take over this week so hopefully I can hit it hard next weekend. I’m aiming to flip the canoe this fall and order finish kit before the end of the year.


Fuselage Drilling Complete!

July 18, 2011

All the drilling is finished on the fuselage now and it’s ready to be taken apart! The last week was spent confirming all the holes are drilled to final size, opening up various holes for fuel lines, vents, and wire runs. Technically I still need to drill the bottom of the 902 bulkhead flanges, but not until I remove the bottom forward skin. A lot of edge prep is done for the interior parts so I hope I can get through the prep process quick enough to start priming in the next couple of weeks. I’m not looking forward to countersinking the hundreds of holes in the longerons!

Below are examples of some of the extra holes drilled during the fuse prep:

A bulkhead flange in the baggage area drilled to the longeron

A countersunk hole for a #10 screw on the forward fuselage.

This photo shows the 1 inch hole for the fuel line pass through. The actual fuel line is only about 3/8" but its held in place by a 1 inch rubber grommet that shields it against vibration.

More Forward Fuselage Work

June 21, 2011

Work travel, a renewed interest in running and enjoying the weekends with the family put the project in low gear for most of June. I have been working on a number of tasks in parallel. It’s definitely not the most efficient way to do things, but kinda of fun to change things up from one session to another. Tonight I finished the preliminary drilling for the Tank Attach Bracket. I spend the weekend making the F-796B angle 4 times (you only need two of them) because I kept screwing up the dimensions. The bolt holes look like they’ll be drilled later.

On the rudder pedal front, the brake pedals are ready to be riveted now. Then I can prep the rest of the rudder pedal assembly and drill the mounting holes in the F-719 forward skin stiffeners. Finally, on the floor stiffener front, the two center stiffeners, are all drilled except for the aft most holes on the cover support ribs. That leaves the two outer stiffeners to take care of once I get the floor skin back in place.

Weekend Update

May 30, 2011

Nothing better than a three day weekend with good weather! In addition to lots of outside time with the fam, I got to dig into the forward fuse some more. Friday night I went through a the forward fuse progress and made a laundry list of to-dos including a drilling sequence for some of the critical drilling on the firewall angles. I did not want to screw those parts up and the instructions in the manual at this point are, shall we say, not explicit. They tell you “what” to do but leave the “how” up to the builder.

First I tackled the connection of the 719 stiffeners to the firewall. I had fabricated the 719B bracket a while ago but waited to drill the holes here until I looked at how others had done it. I ended up using Mike Bullocks method of a 12″ drill bit to drill the two holes in the stiffener and then a angle drill for the hole in the firewall flange. After some careful double checking of measurements, everything came out perfect.

Here’s a shot at the two holes I used a 12″ bit from above (below) get to. Some folks have removed the stiffener and drilled on the bench but I was worried about keeping everything aligned.

Next up was to finish the gussets at the intersection of the lower/auxilery longerons, the firewall mounting bracket and the vertical firewall flange. This must be the most complex intersection yet on the aircraft as three axes converge at the bottom of each side of the firewall. With the gussets I had two rows of rivet holes remaining to drill. I also has already cut the part out according to the plans. Saturday I spent the afternoon with my micrometer and files tweaking the edges until each gusset fit snuggly in place I felt good about all the edge distances.

Here’s a detail of the other gusset. The notch in the gusset is what allows it to fit inside the steel engine mount bracket but ouside the vertical firewall flange. However you can’t let the notch get too big in order to keep your edge distances tolerable. Confused yet? Me too. I took my time and drilled the vertical flange with the skin peeled back. Then used the skin to match drill through the bracket at the horizontal row above. It all turned out good and I’m very happy to move on.

On Sunday I prepped and installed the 902 bulkhead and the 7101 Gear Attach Web. There was a small gap where these parts meet up (see the four copper clecos in the pic above). I added a .020 shim between the parts for a better fit. The foward fuse with the bottom skin cleco’d back on is pretty stiff now. I am going to skip ahead and fit the floor stiffeners next before tackling the fuel tank attach and the rudder pedal install.


Planecation 2011: Day Five

May 20, 2011

I concentrated on the F-717 lower longerons today. In the morning, I trial fit them until getting the twist and the length just right.

In the afternoon, I decided to go ahead and drill the holes for the AN3 bolts that attach the lower longerons to the lower firewall mounts. These are 3/16″ holes so there isn’t much room for error here. First I drilled a #40 pilot hole and then opened it up in steps up to a #13 drill. I used a squared piece of wood to make straight holes. Finally, I finished them to final size with a 3/16″ reamer for super clean holes. They turned out really nice. I’m super happy to get done with this step.

Planecation 2011: Day Four

May 19, 2011

With the firewall attached I could move on to fitting the additional longerons and stiffeners that make up the forward fuselage. Each of these six pieces are made of angle stock and need to be custom cut, twisted and fit into position. In the photo above you can see the top longeron in the bottom of the frame (remember the fuse is upside down right now). In the middle is the forward stiffener and up top is the auxiliary longeron. At the very top (not pictured) will be the lower longeron which is a relatively beefy piece of angle.

First up were the auxiliary longerons. They were pretty straight forward to drill into position using clamps and the skin holes for guides. Again the connection to firewall weldement is important so I took my time here.

Next were the forward stiffeners. These are a bit more challenging because you basically tape them into place to start drilling because there no way to clamp them in place. I got the right one done quickly and felt pretty pleased with myself. Then I got in a bit of a hurry and drilled the first hole in the left stiffener before realizing I had slightly misaligned the fore/aft positioning when I retaped it . Technically the hole has enough edge distance but this stiffener “joggles” over the another piece on the other side and I couldn’t salvage that alignment.

It doesn’t look like much in the photo but the 1/16″ I was off here messed up the seating of this piece on top of the 704 sidewall on the other side. It’s a $6.80 part so not a big deal to order another one. There’s plenty more I can do in the meantime.

This evening I started to trim and bend the F-684 gusset that provides more strength to the lower firewall area. It’s got quite a number of critical dimensions and bends in order to fit correctly. I only got the left one roughed out before running out of gas.

Progress Report

May 8, 2011

Where to start? This should be more like 3 or 4 posts but I’ve been busy with work and family so I haven’t been updating the blog like I should. So here it goes. After finishing the center section riveting, I drilled the 715 ribs on each side as well as all the floors.

The center section then got flipped back over and reattached to the 706 bulkhead. Attaching the 770 side skins was very challenging. I had a hard time getting the holes to match up. It took three days of searching the forums and builder sites for advice to arrive at the solution. You have to basically raise the rear fuse just behind the 706 bulkhead by a good 8 inches. This spreads the longerons a bit and gets those rear holes in the 770 skin close enough to the aft fuselage holes that you can get some clecoes inserted.

After that it was time to match drill the arm rests. Pretty straight forward.

The next hurdle is bending the bottom rear of the 770 skins to conform to the curve of the aft fuse. My first attempt ended with a small crack at the 90 degree bend because I used the steel from my mini-brake and it has a very sharp edge. Joe at Van’s said I could stop drill it and glue in a metal backing but I opted just to order a new skin for $60.

On the second attempt I used a piece of scrap angle that had a slightly rounded edge. This time the bend turned out better but I still ended up with a tiny little crack again. I will just drill and open up that corner a bit to get rid of the crack and help the edges meet better. On the third try with the left skin, I rounded the edge of the angle even more and the bend turned out perfect. I’m very satisfied to have the 770 skins in place and those corners fitted. Next up will be drilling all the holes in the longerons. Yay!

Ribs and Things

February 2, 2011

Tonight I was able to finish up deburring all the holes from match drilling the center section together. In addition I dimpled all the ribs including both 623s and the attach straps. There’s a bunch of little random parts I need to keep an eye on when it comes time to prime everything as they are easily lost.
I goofed on both 727 baggage ribs and missed match drilling every other hole. I need to reattach and match drill when I get the skin down to prep it for final assembly. After some debate I decided to prime the inside of the skin. Never know when that drink might spill.

The Great Debur Fest

January 24, 2011

This weekend I was able to finish drilling all the holes on the center section, countersank the four holes in the front 704 bulkhead, and make the attach straps for the F-623 ribs. Now the 776 skin is off. Once the rest of the parts are disassembled, then it all gets deburred, dimpled and primed. That last part is gong to require some better weather than we’ve been getting.

The Heart of the Beast

January 18, 2011

Happy MLK Day! The family granted me some quality time in the garage this weekend so I was able to get most everything assembled and drilled on┬áthe center section. I had KEXP rockin’ on my little portable radio and the weather was finally mild enough that I didn’t have to wear my bulky winter coat in the garage. On to the build:

The center section is a simple enough set of parts: A couple of bulkheads, 16 ribs and the center skin. However, this is the heart of the fuselage with some very important intersections. The gold piece in the photo above is one-half of the 704 bulkhead. This is where the main wing spar attaches to the fuselage. The gray bulkhead in the back is the 705. It’s where the rear spar of the wing attaches and the seat backs lean on.

All the control systems and most of the airplane wiring route through this section. This means there’s lots of holes to be drilled and formed between parts. It all adds of up an endless list of little steps. If you look close above you can see a spacer between the flange of the rib and the bulkhead. When I first clecoed everything together I forgot to insert these four spacers. There’s no way to slide them in after the fact so I had to take everything apart and reassemble. Oh well, it helped me figure out a riveting strategy for this section.

Here’s 2 out of 8 half circles divots I had to take out of the middle row of ribs. These allow for wire to be routed aft for lights, autopilot, GPS, and ELT or whatever electronic gizmos I’ll want in 5 years.

The F-715 ribs on the outside don’t get drilled until later. So they are just clamped in place for now.

This is actually the topside of the center section. Because I need to drill out the skin, it’s much easier the build this part upside down.

I tried to take a panorama of the workshop tonight but the pics came out blurry. I’ll try again tomorrow and give my version of the state of the union for the RV-7 build. Right now you’ll just have to settle for this picture of the three main sub chunks of the RV sitting in the garage. To the right is one of the wings in the wing cradle. In the back is the center section and in the mid ground is the aft fuse patiently waiting to be finished.

Next up is to finish the drilling, disassemble, debur and dimple everything. Then I have to figure out just where to prime these parts as the weather is so iffy this time of year. See you in a few days.