1070- Elevators- p.9-15 step 8-9

Elevators- 2 hrs 15 mins (Elevators 66:27, Empennage 189:26, Total 210:22)
Rivet count: 66 (Total 3,570)

Well, these elevators are just dragging on for an eternity. Not only did I not get to finish them over the holiday weekend, but I'll be pushing 70 hours of labor by the time I'm done. 

Quickly, we finished up the blind riveting from yesterday. Then my pregnant wife helped with cutting the lead weights. She's wearing a respirator just in case, and the garage smelled of acetone, so double whammy. It turns out that cutting the lead indoors was a bad idea. Little pieces went flying everywhere! After two pieces, I noticed and we stopped. Here, the tape breaks off for a half hour while I took the bandsaw outdoors and finished the pieces there. The removal of the backstrip from two of the weights was a royal pain in the rump. Why doesn't Van just send us the pieces already cast to size? The bandsaw heats up the lead pieces significantly. The best method for me was to trim off the strip a sliver at a time. When the weight became too hot to handle, I soaked it in a jar of water and worked the second weight. I swapped back and forth and got everything accomplished. The driveway was a mess after. I tried to vacuum as best I could, but Mother Nature is taking the hit on this one for lead poisoning. I want to keep my wife and dog as far away from the lead dust as possible. A chisel worked great for "deburring" the edges of the weight as we come back to video. 

Next, we wrapped the weights with electrical tape. I've seen others do this, and Im not really sure the reasoning. The weights do look much better, and I would assume they are now better protected from bending, chipping, and contaminating other places. With the weights wrapped, it was time to break out the torque wrench and bolt the weights on. Amazingly, it took about 10 minutes per elevator to do so. 25 inch pounds seems like a really low torque setting for these bolts, but that's what the literature calls for. To finish the night, we screwed the cover plates to the bottom skins. These will eventually come off again for further assembly of trim cables, etc. But they are secure in place now. The elevators just need the piano hinge to attach the trim tabs and we are complete! -M

postscript- Ironically, a year ago on Thanksgiving weekend, I was bending the leading edge of the rudder and working with the lead counterweights. I found that interesting... We'll have to see what next Thanksgiving weekend has in store for us....

1069- Elevators- p.9-15 step 3-7

Elevators- 2 hrs 32 mins (Elevators 64:12, Empennage 187:11, Total 208:07)
Rivet count: 66 (Total 3,570)

This is actually multiple days worth of work, but due to the Thanksgiving weekend, I wasn't able to get a solid chunk of time to work on the elevators. 

I started out by bending the edge of the top skin so that it will sit flush after riveting the two skins together. Then we used the duct tape and PVC pipe method to roll the leading edges of the elevator and cleco'd them together. After clecoing, there were still a few places where the edge wasn't flush. This simply required undoing the clecos and bending the edge more evenly. It's not perfect, but I'm not too concerned. It will eventually get filled in and smoothed prior to painting in the future. Thankfully, that's all riveted together and complete. My hands are torn up from bending cold metal.

Then we blind riveted the cover plate pieces together. Last, I marked off the lead counterweights for the trimming that will take place tomorrow. The video cuts out before I finished riveting the second elevator. I actually left a few rivets for tomorrow as well. -M

1068- Elevators- p.9-14 step 11-12 & p. 9-15 step 1-2

Elevators- 2 hrs 10 mins (Elevators 61:40, Empennage 184:39, Total 205:35)
Rivet count: 78 (Total 3,504)

Today was a short day of work. We removed the cleco's after giving the sealant more than enough time to cure. We also cleaned out the rivet holes of extra sealant. Then we riveted the ends together. I'm not sure if the method that I used for the elevators was different than for the rudder, or if it is that my riveting finesse has increased, but it was alot easier to accomplish this part than what I remember from almost a year ago. It even looks nicer when finished.

After, we finished riveting the skins to the end ribs. My squeezer is too big, so I ended up having to use an MK-319 rivet on the last hole of the bottom elevator skin (it matches the two other MK rivets on that skin that are called for in the plans. Finally, we blind riveted the close out tabs to finish the aft ends of the elevator.

Next we will finish up with the leading edge, then the counterbalance weights, and finally the trim tabs. I'll be done with the elevators before December! -M

1067- Elevators- p.9-14 step 7-10 & p.9-17 step 8-10

Elevators- 3 hrs 50 mins (Elevators 59:30, Empennage 182:29, Total 203:25)
Rivet count: 78 (Total 3,426)

Tank sealant still stinks. Literally. It's also a pain to work with. 

Today we managed to rivet the trim tab pieces together. After, we applied the foam tabs to the trim tabs and cleco'd everything together to let the sealant cure.

Then, we got to work on the elevators themselves. We applied sealant to the foam tabs in between the elevator skins. Then, we applied sealant to the trailing edge wedge. We cleco'd everything together and applied weights to let everything sit and cure for the next few days. I can't tell if it's a 45 hr cure or a 112 hr cure time. So I guess I'll be taking the conservative route and wait until Friday. Luckily, in the meantime, I can still work on other random parts such as the counterweights. -M

1066- Elevators- p.9-13 step 1-3 & p.9-14 step 1-6

Elevators- 4 hrs 56 mins (Elevators 55:40, Empennage 178:39, Total 199:35)
Rivet count: 400 (Total 3,348)

The first hour of this was actually a few days ago, but I forgot to upload it then.

Today's work was centered around attaching the front spars and rudder horns to the assembly. The flanges were all riveted except for the part that will have the hinge for the trim tab, and the remainder of the skin was also riveted on. 

Then the counterbalance assemblies were attached and riveted as well. The pieces finally look like something recognizable. Tomorrow I get to work on the trailing edges and use epoxy sealer as well. The pieces will have to sit for a few days to cure, so it will be at least until next weekend before I finish the elevators. I'm still sitting at that 75-80% of expected work hours [I had forecast 80 hrs for the elevators] to get the project done. Being on schedule (despite the six month layover) is always a nice thing. -M

1065- Elevators- p.9-12 step 1-6

Elevators- 3 hrs 45 mins (Elevators 50:44, Empennage 173:43, Total 194:39)
Rivet count: 222 (Total 2,948)

Happy Veteran's Day! Thank a veteran for their service today.

Today's progress was visually minimal, but time consuming nonetheless. We started out by riveting the elevator rear spar to the skins. On the bottom skins, the entire length was riveted. On the top skins, only part of it was, since the piano hinge that attaches to the trim tab still needs to be added in a later step.

The second skin was positioned and the rib halves were cleco'd in place, and then the rear spar was riveted to the second skin. That special RV-10 bucking bar was finally used today. I remember reading that there was a potential second use for it, so I'll do some research. Otherwise, it's time to pass along the tool to another builder via sale or donation soon.

Last, blind rivets were used to attach the previously cleco'd rib halves. 4 rivets per rib and 16 ribs makes for an interesting 75 minutes of working in cramped spaces and trying my best to not scratch up the primed surfaces. Well, now the two halves are together. All that's left is to add the front spars, and seal/rivet the trailing edges. I think there's a few random pieces left as well, but the major stuff is assembled. -M

1064- Elevators- p.9-11 step 3-6

Elevators- 3 hrs 20 mins (Elevators 46:59, Empennage 169:58, Total 190:54)
Rivet count: 168 (Total 2,726)

Unfortunately, the first hour of work today was spent correcting a mistake from yesterday. After six months, I forgot the order that the ribs went on the top and bottom skins. I also failed to look at the picture in the instructions. I had to drill out 64 rivets. I'm really good at that now!

Then I finished riveting the ribs to the (correct) skins, and then used the hand squeezer (by the way, 4-X rivets are a pain with the hand squeezer) to attach the rear spar to the ribs. Also included in there are the two shear clips and elevator gusset on each elevator. It's nice to see the elevators coming together. -M

1063- Elevators- p.9-10 step 2-7 & p.9-11 step 1-3

Elevators- 5 hrs 32 mins (Elevators 43:39, Empennage 166:38, Total 187:34)
Rivet count: 404 (Total 2,558)

Let the riveting begin! We had a great Sunday afternoon to get started on these elevators. Started by riveting the counterbalance ribs together and then the counterbalance skins to the ribs. These steps alone took 2 hours. 
Then we started working on the elevator spars and added the reinforcement plates, nutplates, and root ribs. After the root rib was attached we were able to attach the elevator horns. This was 1.5 hours.
Then we attached nutplates to the reinforcement plates for the access panels and then the reinforcement plates were backriveted to the skins. Lastly, we backriveted the rib halves to the bottom skins. -L even helped out with three of them! The last 2 hours.
The top skins are next, but now it's time for studying. Likely won't be able to work on this again until late in the week, if not all the way until next weekend. Tuesday is a holiday, so I may have to take a study break and get those top skins done. Checkride prep and academic exams will have my full priority this workweek. -M

1062.1- Elevators- p.9-10 step 1 & p.9-17 step 7

Elevators- 6 hrs (Elevators 38:07, Empennage 161:06, Total 182:02)
Rivet count: 0 (Total 2,154)

Finally had a day where the weather cooperated! I was able to devote the whole day to getting the elevator parts cleaned and primed. Having left the parts sitting out for 6 months since I last worked on them, it was definitely required to give them a wipe down with an acetone rag. I debated scuffing them again, but figured the primer would be just fine. I'll find out the verdict in years to come.

First I primed the four skins to give myself a nice big area to practice on. I remembered to mask off the areas where the foam tabs go, but forgot to mask off the area where the trailing edge wedge will go. I'll need to figure out something to scuff or sand off the primer in that area now.

After, it was 68 more parts to prime. I'm really glad I was able to get it all done in a single day. Now I can put the tailcone on hold and start riveting together these elevators! -M

 

1062- Tailcone- p.10-8 step 1-3

Tailcone- 2 hrs 24 mins (Tailcone 18:34, Empennage 155:06, Total 176:02)
Rivet count: 0 (Total 2,154)

This is actually multiple days worth of work merged together and all in one video. Straightforward progress. Attached the aft-most bulkheads and the Aft Bottom Skin and then attached, cleco'd, and drilled the left side skin and the associated stiffeners behind it. All I can say is that I'm glad to be done with it. 4 hours of drilling over the past few days has been fun, but I'm ready for a change of pace. Looks like we get to go back to manufacturing smaller pieces next in the plans. -M

1061- Tailcone- p.10-6 step 1-3 & p.10-7 step 1-7

Tailcone- 4 hrs 41 mins (Tailcone 16:10, Empennage 152:42, Total 173:38)
Rivet count: 0 (Total 2,154)

First thing today was to make the longerons. They needed a small cut off the end, and then a mark for the bend and a 1/4" hole with cut-outs to the edges to make a v-shape. The bend part itself was a pain. The vise that I have works well for holding things for to work on and drill, but not so well for heavy-duty jobs. I eventually hammered the 2 degree bend into them, with only minimal damage to my table.

Once the longerons were complete, the admin steps are done (for the most part) and we can begin assembly of the tailcone. I don't have sawhorses and I didn't feel like making any so I improvised with my ladders. The bottom skin gets hung upside down and the frames and bulkheads are cleco'd in place. Then the bottom stiffeners are located and match-drilled to the skin. After the right side skin was positioned over three more stiffeners. After clecoing the side skin, the next three stiffeners were match-drilled. At 250 holes on the skin, this process takes some time. 

Thankfully, the tailcone is beginning to resemble something. See the video below to take notice. Thankfully, daylight savings gave me back an hour to work on the parts a bit extra today. The aft frames and bulkheads are next followed by the left side skin and the three associated stiffeners. -M

1060- Tailcone- p.10-5 step 3-4

Tailcone- 3 hrs 18 mins (Tailcone 11:29, Empennage 148:01, Total 168:57)
Rivet count: 0 (Total 2,154)

The admin steps for the tailcone are nearing the end. Unfortunately, that doesn't make the time any better. Three hours were spent today simply to cut, deburr, and mark the 12 stiffeners. That's a long and boring three hours. In case you are wondering, I went out to dinner with wife and friends, and finished the last 25 minutes of work after returning- hence the outfit change in the video.

First, the two ends were marked off at a 45 degree angle and then cut. Then, the cut was smoothed over and the rest of the part's edges were deburred. Finally, the stiffeners were lined to mark the future site of the rivet line. I again have new-found appreciation for these match-drilled parts compared to the builders of old that had to mark off every single piece and part they manufactured. Speaking of modern advances, they sell tools out there that allow you to mark off a line by running the tool along the edge of the piece. I saved myself the $19.90 (or whatever the cost is on a parts website) and just marked off the line the old fashioned way. 

Next, I will manufacture the longerons out of angle stock and bend those to fit the side skins. And once that is complete, we finally get to start assembling the tailcone pieces!! -M