Build Log RV-10 #1

Blog for a Vans RV-10 Airplane Build

Aileron Trim System

Purchased the Aileron trim system and decided to get it installed in the wing before riveted on the bottom skins.

This was fairly quick and was straight forward.  Pulled out all the parts, cut them as directed, deburred all the edges and clecoed together for final drilling.

Got all the final drilling done and prepped all parts for priming.  While they were drying, I went ahead and ran the wires the the wing conduit to the wing root.  Only going to leave enough wire to get to the outer fuselage as I plan to put on a some bulkhead CPC connectors so that if I ever need to remove the wings, the wiring connections will not be an issue.  Also on the ends of the wiring, I am installing AMP connectors again so that the items can be removed and inspected as needed.

Parts are all dry now so I finished Riveting the items together.  The trim servo attaches to an inspection plate so that also needs to be measured for 8R8 screws that will go through the inspection plate into the bottom of the servo attach brackets.  These also need to be dimpled for flush # screws.

Now that that is completed, the last part is to attach a couple of brackets to the aileron pushrod assembly.  Got the locations marked per the directions and installed with rivets. 

The servo can now be screwed to the inspection plate and then springs coming from the aileron pushrod assembly can be connected to the arm coming off the servo.  Once those are on, connect the wire connectors and attach the inspection plate to the bottom wing skins.  Finished.

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Control System

This weekend I started working on tghe control system.  However, mad some mistakes and had to quit.

Started off by fabricating the elevator push tubes.  Got them cut to length the using the template, marked the holes to be drilled for riveting the threaded rod ends.  Holes were marked and drilled.  I did do both tubes at the same time so that I could get them coated on the inside with Akzo primer.  Made up a batch and poured inside getting them coated.  Set aside to dry and will finish riveting the ends in tomorrow.

Moved on to getting the jam nuts put on all rod end bearings. Then worked on the Aileron pushrods.  Installed the rod end bearings in each and all jams tightened to where the pieces are to the correct length.

I then started to work on the elevator idler arms and got them put together with clecos and then started to match drill.  For some reason I decided to not align the holes in the flange bearing and proceeded to drill completely new holes.  Once I realized this, time to stop and order a new flange bearing.  This probably was not a big deal but bothered me enough to set aside until new part arrives.

The pushrods then dried overnight so I installed and riveted the threade rod ends in and then got a coat of primer put on the oustide.  Again set aside for a day to let dry. 

While they were drying I moved on to the controls sticks.  Got the control stick base aligned up correctly and drilled to the control sticks.  This was a bit tricky but took my time and everything worked out good.

I then got the control column prepped and installed into the fuselage, bolted and torqued per specs.  Next was to get the control stick bases installed to the control column but there are a couple of bronze bushings that need to be opened up enough for a AN4 Bolt.  I did not have a reamer so I tried to use a 1/4 drill in a drill press to get them to the right size.  This ended in complete failure and ruined the bushings. 

Now that I have a couple of different pieces that I screwed up on and ruined. I am stopping with this section and will finish when I get new parts from Vans.

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Aileron Construction

Started October 15th, 2010 - 47.5 hours

Before startign this step I decided to construct the cradles that hold the ailerons in a vertical postion so it is possible to reivet it.  Cutout a couple of boards using the flap nose rib as a guide.  The only purpose of this cradle is to support it so it is suitable for riveting.

Gathered all the pieces tonight that will be used for the entire aileron construction. Checked all the ribs flange angles so and adjusted to 90 degrees. Clecoed the ribs and doublers to the spar.

The hardest part with these is keeping the parts in the right place.  The pieces are pretty much identical when it comes to the ribs and the skins.  I temporarily placed all the pieces in their respective spots and labeled them in multiple spots so they could be easily identified.  Made the rest of the process much easier by taking the guess work out of it.

Got all the ribs and counter balance attached.  A bit tricky but also got the counter balance match drilled to the A-1004 ribs.  Not sure why, but you only need to drill the top attach pioint on the inside rib to the counter balance.  Could easily do both, but oh well!

Clecoed the main ribs and hinge bracket to the spar, match drilled and countersunk the appropriate holes.  Also did the same process for the outer hinge bracket and main rib.  Then took everything apart.  That is a shock, put together, take apart, put together, take apart...

Marked all the skin stiffeners and cut using a band saw.  This takes a bit of time but not hard.  Just make sure that you know where you are cutting.  The last  13/32" is cut off of the aft portion to make room for the trailing edge.  When attaching them to the skins, double check the placement and configuration so that you do not put the ribs the same for the top and bottom. They are not rivete together so ther are offset a bit when in place.

All stiffeners are placed, match drilled and marked accordingly so they can be placed back into their correct postion when riveting.  All were taken apart, deburred, dimpled, Blah Blah Blah as normal and everything primed.  Let them dry overnight and back riveted all the stiffeners in place.

Cleecoed the assembly together, ribs, spar, main ribs and now completed skins.  It is important I guess that the aileron lay flat on the table and weighted down to make sure that it is completely straight while it is match drilled.  Also match drilled the trailing edge and then countersunk both sides perpendicular to the surface.  All the rest of the parts have now been deburred, dimpled and primed.  Time for final assembly.

Final assembly starts with the cunter balance being bolted to the ribs and then place in the nose skin. This final assembly is done in the cradle.  This does make it much easier.  It was then time to insert the spar and rivet in place.  Then insert the top skin, rivet together to the spar, then on to the bottom the same way.

Not that the skins are in place and riveted to the spar, the main ribs are inserted and riveted and then clecoed the trailing edge in place.

The rivets are is a specific sequence and you jump around a bit.  Make sure that you read through the instructions a coupel of times and understand this.  Can be done in the wrong order very easily.  This is sure so that the aileron stays flat and continues to be once riveted.  This is all done so I used some tank sealant on the trailing edges, inserted a cleco in every hole and clamped to the work bench for a couple of days while it dries.  Then place all the rivets.

Fabricated the A-1012 AND A-1013 That are used in hinge brackets as spacers for the aileron push rods.  All hinge brackets are attached with bolts and nuts.  Before attaching the aileron to the wing, attach the pushrod to the hinge bracket.  I did not due this for one of the ailerons and it was very difficult to get the spacers, washers and nuts on the bolt attaching the pushrod to the aileron hinger bracket.  Worked great doing it before on the other aileron.

Ailerons are all done.  Not sure if it is just me, the process of construction or what, but man did these things go on forever.  This was one of the most trying parts to build so far.  Seems like they took forever and not much viewable progress.  Anyway, yipee they are done and now on to the flaps.

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Aileron Actuation

Started October 1, 2010 18 hours

The next step in the construction process is to get the bottom wing skins on.  After looking at others construction process and reading the the manual, it seemed that it would be a better choice to jump forward to the aileron actuation part first.  Seems as though it would be much easier to get these at least installed and set while you can still get into the wing.

 I am going to do the regular install of the actuation system and have decided to add aileron trim, so will be doing that install also before closing up the bottom of the wings.

Not much to say here.  The directions and pics are pretty straight foward.  The only thing to watch is to make sure that you put the torque tube in the correct way.  The small difference when drilling torque tube subassemblies make a difference.  If they are in the wrong way they contact the inner wing rib and does not allow enough throw.

I did finish up the ailerons and then came back to this step and attached the pushrods to the bellcrank and the aileron bracket.

This step is now finished.

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