David's RV-10 Build

Just another RV-10 builders log

Category: Wings

Left Leading Edge

17) Leading Edge, 19) Stall Warning System
Comments

Today I really got started on the leading edges. I decided I am only going to build one at a time to simplify the parts management. I decided I would start with the left as there was a lot I wanted to do with it. I started off by cutting some notches in 2 of the ribs. Next I inserted the ribs & the J stiffener. I left it all together after match drilling and elected to start the stall warning system since I had a lot of open access. The first thing I did was cut the access port. I was a nervous wreck cutting a big hole in the skin but it came out fine. Next I drilled the 2 holes to create the switch hole in the very front of the leading edge. I finished the night up by assembling the stall warning switch. Once I start taking the leading edge apart, I will have to come back to this section to make sure I have all the appropriate holes dimpled, riveted, etc. I am trying to get Duckworks to send me a couple of the cutting diagrams so I can cut the skin in advance.

Rib’s getting ready to be modified.

Leading edge assembled, match drilled, ready for disassembly

Preparing the access panel

mounting holes drilled out

1/2″ radius corners

access plate doubler

access plate

stall warning switch port

stall warning switch

Right Top wing skin

16) Top Wing Skins
Comments

Today Corey & I really did got at the right wing. I’d say we did probably about 3/4 to 7/8s of all the rivets to be done. I also put some conduit in the ribs. I don’t think I posted before, but I am using the 5/8″ black conduit from Van’s. I ordered 50′ of it and I have ALOT left over. After Corey left, I reorganized my toolbox a bit and really cleaned it out. This was well needed to be done. I also ended up making a wood block to hold my countersinks. I am not sure why I didn’t do this before.

Top Left Wing Skin Complete

16) Top Wing Skins
Comments

So I’ve been slacking pretty hard on the updates as well as slacking on working on the plane. I really don’t recall any specifics other than alot of dimpling, sanding, priming and riveting. I have a couple of dings in the skin which im not thrilled about, but I will take care of once it becomes time to paint. Once I got the the left skin riveted, I installed some 5/8″ conduit as well as the Pitot & AOA lines.

J Stiffner placed

Skins cleco’d. Ready to match drill

Inside of wing

Excess hidden away

The top skin in all its glory

Rear spar Complete

14) Wing Ribs, 15) Rear Spar, Tools
Comments

Today I ran over to Home Depot and picked up some new Dewalt 20V Drills. I really did not want to buy any of the 20V stuff, but they stopped producing the one drill I needed in 18V. So I ended up getting the 20V 90d Angle Drill (tool only) and a combo kit that had a 1/4″ impact, drill/driver, 2 batteries, a charger and a bag. Once I got to the shop I immediately tested out the 90 degree drill and it did exactly what I needed it to do. I was able to drill out the conduit holes that I neglected to do earlier. This was followed up by tidying up the shop a little bit.

Next I grabbed the rear spars and mounted the doublers to them and began match drilling.  After match drilling one spar, I had to make a hole in one of the doublers match the spar. My solution was to use a unibit to take out a big chunk of the material and then dremel the rest out. With a cutting blade I cut out what i could. then i cut little notches to the edge. Next I used a dremel drum sander to smooth out the roughness.

next i mounted the spars to the ribs and matched drilled those

once that was completed I began disassembling and deburring, cleaning and priming. Once the primer was dry I cleco’d everything back together and began riveting.

Aileron Brackets Completed

15) Rear Spar
Comments

Didn’t do much today as well either. I did prime and complete the brackets I started yesterday though. After buying 3 more cans of EZCoat and placing an order for 2 cases. I primed the parts from yesterday. Next I used a 7/16 , 9/16 sockets and my vice to press the bearings into place.

next I cleco’d the assemblies together and  began riveting. I started with the flush rivets first and then randomly did the regular rivets. This is to attempt to prevent warping of the entire assembly. They looked straight to me.

Wing Rib’s Complete

14) Wing Ribs, 15) Rear Spar
Comments

Today I was greeted by a box from the UPS man from Avery Tools. I got my SafeAir1 kit as well as some other goodies. There really wasn’t much to accomplish today. I finished up the ribs in the left wing. After that I pulled all the parts for the rear spar and started on the Aileron Hing Bracket Assemblies. First thing was to trim 2 of the 4 spacer brackets. Then I cleco’d the assemblies together and match drilled the #30 holes. Afterwards I marked each assembly and began deburring and scuffing. I need some more primer so I called it a night.

safeair1 kit

 

Right wing complete (mostly)

14) Wing Ribs
Comments

Today I completed the Right Wing ribs for the most part. I put a post on VAF regarding conduit sizes. I was unable to locate 3/4″ conduit locally so I want to use 1″. But im not sure if the structure will support the hole size. Getting the rivets in wasn’t so much a hassle, but the bolts were difficult in figuring out what went where as its so tiny. Tomorrow I plan on finishing up the left wing and starting the rear spar.

 

 

Primer Time

14) Wing Ribs
Comments

I have recently discovered how the egyptions built those pyramids and it really works. I had 4 people + me scuffing, deburring, and cleaning the wing ribs. I think we got all of them done in under 2 hours. After they dried a bit in direct 90 degree sunlight. I blindly primed all these ribs. I was able to get everything primed with just shy of 2 1/2 cans of primer. Which was good as I was running on empty on the last rib. Tomorrow I am going to call SEM and see how to become a dealer so I can get this stuff cheaper. I buy it buy the case 2 or 3 at a time and no one will offer price breaks. I also ordered the SafeAir1 kit from Avery today as well as some other bits and pieces. Those should be here in 2 days.

 

im pretty tired and i forget what these are called, but here it is.

 

all the ribs mounted on the spars ready to rivet.

i also drilled out the pitot holes to 3/8″ of an inch. The plans call for 7/16 but the SafeAir1 kit uses smaller snap bushings. I also had to add a 2nd hole for the AOA line. I just measured 1″ x 1″ off the edge. I*HOPE* this does not cause an interference issue in the future.

Tomorrow I am going to try to locate some 3/4″ innerduct for the cable run. If I cannot find any I will see if I can use the 1″ that I have laying around.

David's RV-10 Build © 2015