1072- Elevators- p.9-18 step 3-8 & p.9-19 step 1-2

Elevators- 2 hrs 12 mins (Elevators 71:07, Empennage 194:06, Total 215:02)
Rivet count: 58 (Total 3,686)

The Elevators are finally finished!!! I started them 11 months ago.... Talk about a long time for progress. 

Today's work was the exact thing I did last week, but mirror imaged for the right elevator. Not much to report here other than it's finally done! 

We'll find a place in the house to store these parts, and then continue work on the tailkit that was started months ago. -M

1071- Elevators- p.9-18 step 1-8 & p.9-19 step 1-2

Elevators- 2 hrs 28 mins (Elevators 68:55, Empennage 191:54, Total 212:50)
Rivet count: 58 (Total 3,628)

Wow, I really can't believe it's been nearly two months since I've done work on this. School has been kicking my butt. Christmas was fun, but I spent most of it traveling to see family. I was hoping to get the elevators done before the new year. Now, the past two weeks have just been brutal, and the cold weather makes it even harder to go out and work on things. Enough excuses. I finally got my safety wire and pliers ordered and was ready to finish the elevators. The first part of this video was from 8 days ago on the 11th. I forgot to upload it and the timelapse merged both days into one video.

I've been following the last two pages of the elevator manual. Cut the piano hinge to size and then drilled each half to the elevator and trim tab. The bending of the piano hinge was surprisingly easy, but still took quite some time. Finally, a little bit of safety wire to secure the bent hinge in place and the left elevator is complete. About two more hours and the right elevator will be done too! -M

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

 

1055- Elevators- p.9-17 step 5-6

Elevators - 1 hr 19 mins (Elev. 32:07, Empennage 136:32, Total 150:28)

Rivet count: 0 (Total 2,154)

It may have been a short 1.5 hrs, but the construction on the Elevators is complete! If I had more time, I'd have started the acetone cleaning process, but I'll save it for tomorrow. I'll also bust out the alodine tanks again tomorrow, and be on my way to getting priming done in preparation for riveting next week!
Tonight, I took apart the trim tabs, and deburred edges and holes, then dimpled all holes except for the two lines of countersinking. Very short night, but progress! -M

1054- Elevators- p.9-16 step 4-5 & p.9-17 step 1-4

Elevators - 2 hrs 34 mins (Elev. 30:48, Empennage 135:13, Total 149:09)

Rivet count: 0 (Total 2,154)

Started tonight by finishing the main bend in the trim tabs. I used a makeshift brake and then settled for hands. This worked out really well until the next step which is to bend the side tabs on the trim tab. All the previous bending was negated while trying to get tools, wedges, and rivet guns in the tight spaces. I def screwed up one of the four corners, but not so bad to warrant a new part. I'll keep building for now, and if I have to reorder, then I will.
Next, I deburred the edges of the trim tab spars and then make the 15 degree bend in the two bottom edges of the trim tabs. Easy enough. Then, I used a washer to measure out the arcs on the trim tab brackets which I cut off with the bandsaw. I felt using the washers was a whole lot more accurate than eyeballing it, AND since the pieces sit back-to-back, it guaranteed me consistency and now the pieces are flush with each other. A little more edge deburring before match-drilling everything to end the night. 
Hole deburring and dimpling/countersinking are next for tomorrow and then its cleaning and alodining time once again. I was originally planning for 80 hours on the elevators. I would expect to be right around 40 by the time I finish priming. Seems I'll be able to make up for a little more time on this piece as well. -M

1053- Elevators- p.9-9 step 7-8 & p.9-16 step 1-3

Elevators - 2 hrs 2 mins (Elev. 28:14, Empennage 132:39, Total 146:35)

Rivet count: 0 (Total 2,154)

Started off the day with a quick trip to the airport to help -E with some soldering for his RV-8. While I was there, I also managed to get into -B's hangar and use his vise-grip dimpler for the 12 holes from last night. It worked like a champ, and I saved myself $45 as quoted in Avery as the price for the tool. Nothing like great friends. Thanks -B!
At home, I started by making the bend in the trailing edge of the skins for riveting the elevators later on. The next step called for scuffing the locations where the foam ribs would attach, but i had scuffed the whole skins already. Later on, I'll have to mask off these areas so I can prime everything but them. Then it was time to jump ahead 6 pages in the plans to work on the trim tab pieces, but first the directions called for fabrication.
First, the wooden pieces that will hold the trim tabs together. I made eight instead of six expecting I'd screw up a few, and sure enough, I screwed up on one. Seven. Then I fabricated the six foam ribs for the trim tabs. This was the easiest cutting job ever. Last step was to scuff. I went ahead and scuffed all the trim tab pieces while I was at it. I'm in town with -L for the second time this year, so I may actually get to work on this during the weekend. If the weather holds this week (Rain forecast for Monday), I should be able to prime parts and begin riveting by midweek... -M

1052- Elevators- p.9-9 step 3,5,6

Elevators - 2 hrs 2 mins (Elev. 26:41, Empennage 131:06, Total 145:02)

Rivet count: 0 (Total 2,154)

Every night a little closer. I spent an hour just scuffing the rest of the parts of the elevators. Also I dimpled all the rib halves, as well as the tip ribs. I am still missing the last three holes on each end of the E-903 tip ribs, and spent a few minutes trying to get the pop rivet dimple tool  to work. Even the mandrel for this tool is impossible to work with in such a tight space. Hopefully -E or -B have a vice grip dimpler at the airport because that's the only thing I've found online that works. I really don't want to spend $20 just for the modified grips, but I will if I have to. Lastly, I countersunk the trailing edge on both sides. Next I need to add bends to the lap joints on the skins and then I'll be skipping ahead a few pages to work on the trim tabs so i can get everything alodined and primed at the same time. -M

1051- Elevators- p.9-8 step 1-4 & p.9-9 step 1,2,4

Elevators - 2 hrs 19 mins (Elev. 24:39, Empennage 129:04, Total 143:00)

Rivet count: 0 (Total 2,154)

As promised, tonight consisted of scuffing and dimpling: front spar, rear spar, root ribs, wingtip ribs, and shear clips. There was also a little bit of countersinking too. My hands hurt from using the squeezer.
The most difficult part is arranging the squeezer to get into the hard to reach areas. I have even resorted to using the pop rivet dimpler in some areas. I did screw up the first shear clip and had to flatten the dimple before dimpling the opposite direction. Otherwise, the steady and monotonous work continues, and we are two hours closer to getting the elevators complete! More dimpling and scuffing to follow tomorrow. -M

1050- Elevators- p.9-7 step 9

Elevators - 2 hrs 23 mins (Elev. 22:20, Empennage 126:45, Total 140:41)

Rivet count: 0 (Total 2,154)

What a great day to start dimpling... Unfortunately, I only made it past four parts, but they are the most difficult as the skins. Luckily all the holes were easily accessible, it was just a lot of them to get through. Also, page 9-7 is finally complete after 15 calendar days to get through it!! I took a quick look ahead, and progress (page wise) should crank up now. There is quite a bit of dimpling and machine countersinking left to accomplish on these elevators. Until tomorrow, -M

1049- Elevators- p.9-7 step 8 part 2

Elevators - 2 hrs 1 min (Elev. 19:57, Empennage 124:22, Total 138:18)

Rivet count: 0 (Total 2,154)

I finished the second half of the deburring portion for the elevators! Now on to the dimpling starting tomorrow. Amazingly, part 2 took me exactly the same amount of time as part 1. Consistency!? Earlier today, I also submitted the order for the RV-10 wing kit. It may be ever so slightly too early, but I wanted to take advantage of the lower prices before they increase tomorrow. Things are getting exciting around here! -M

1048- Elevators- p.9-7 step 8 part 1

Elevators - 2 hrs 1 min (Elev. 17:56, Empennage 122:21, Total 136:17)

Rivet count: 0 (Total 2,154)

Step 8: Deburr all the holes. Four words that are going to take me four hours. How depressing. At least I'm half way after tonight. I'm also thankful for the electric drill-mounted deburring bit because this would have taken me much longer otherwise. I did all the parts for the left elevator tonight. Right elevator next week before I spend a few days scuffing and dimpling. Here's the video of me drilling away... -M

1047.1- Elevators- An exercise in dimpling

Elevators - 14 mins (Elev. 15:55, Empennage 120:20, Total 134:16)

Rivet count: 0 (Total 2,154)

I'm exhausted. So much so, that this is it for me tonight.... I can't believe I'm spending almost as much time writing this post as I spent working on the project tonight. So all I did tonight was dimple 14 nutplates, but I learned a bit in the process. Here's the pic, then I'll explain myself for those who are bored and looking for something to read.

I had previously ground the edge off the female #40 die as you can see in the pic. As explained by Chapter 5 of the Van's handbook, this allows the nutplate clearance to get the edges dimpled without being crushed. The "After" example is on the right in case it wasn't clear. I removed the spring from the dimpler to allow the two die halves to rest against the nutplate for better control. What I learned was about efficiency vs. quality. Specifically dealing with the hammer used on the dimpler. I started off using the rubber mallet. That seems to work really well for the aluminum pieces that bend so easily. The mallet is forgiving and quieter. However, for the harder steel such as that on the these nutplates, the mallet was just bouncing off the dimpler. It was taking 3 or 4 strikes to get the steel to even start bending, and even then it wasn't fitting evenly between the two dies after (only half dimpled essentially). Additionally, the dimpler was starting to damage the head of the mallet too. I switched to a regular steel hammer and it made quick work. Just one strike was good enough, though I gave it two just to be safe. The nutplate was flush with the dies, and the "fit test" on the elevator plate was perfect. Of course, just one drawback, the hammer requires more precise striking and also requires each "whack" to be pre-positioned making the work much slower. So it's a classic case of quality via slow work, or quantity via assembly line output. None of the above is anything groundbreaking, but it is still amazing to me to see just how much or how little attention to the details can be focused on such a large project as this. I'm sure this will be one of many learning points in the coming years, but for now, it's bedtime. We start deburring all 18 billion holes on the elevator tomorrow.... -M