Build Log RV-10 #1

Blog for a Vans RV-10 Airplane Build

Wing Spar

Started on Feb. 19, 2010 Build Time 23 Hours

Construction of the main spars started with  removing the protective  plastic from each spar.  I decided to work on  both wings at the same  time rather than each individually.

Located the main spar web extension and spar splice plates.  Clecoed  them into place and final drilled with a #30 bit.  You then take them  off mark them so they can be orientated in the same way they were final  drilled.  I then deburred, prepped them for primer, then primed.

Once the primer had dried, it was time to re-cleco the splice plates  and  extensions back into place and rivet with AD4263-4 rivets.

Next was to fabricate upper, lower, top and bottom wing box  J-stiffeners.  Cut to the length specified and then used spring cleco  clamps to hold them on to the main spar flanges, making sure that there  was 1/16th sticking up above the spar flange.  Once in place, match  drill with a #40 using the holes in the main spar flange as a guide.

Once completed, they are to be removed and stored for later on in  the  wing construction.  I decided to deburr and prime them before  storing.

Now that the wing box stiffeners are removed, you run a  #40 drill  through every 3/32 hole that was not already drilled.  There  are a lot  of holes.

Then on to countersinking all the holes.   Using a countersink stop, I  set it first to do the fuel tank  nut-plates and the holes for attaching  the side of the wing ribs, the  set a bit deeper for countersinking the  skin attach holes.  These are a  bit deeper because it has to accept the  dimple from the skin instead  of just a rivet head.

Now that all the holes are countersunk, I  prepped and primed the holes  for the alodine that was removed.  Once  dry, started to rivet on all the  nut-plates, 66 per spar. After all the  nut-plates are riveted in place,  the nut plate screw holes must be  countersunk to accept the skin dimple  and a #6 or #8 screw.  The  nut-plates must be riveted on before this  task because you use the  nut-plate screw hole as a guide.  Then again  these holes must be primed  where the gold alodine has been removed.

Finally all the holes have been drilled out, countersunk, nut plates  riveted in place and all holes re-alodined and primed.

The  next step was to fit the fuel tank attach nut plates and wing attach  nut plates in the web of the inner spar.  Good thing I double checked  all these plates because at first I had them placed on the wrong side of  the spar.  Good of been a bad mistake. 

The holes have been  match drilled, primed and nut plates riveted to the  spar.

It  was now time to fabricate the tie-down brackets. I decided not to use  the factory supplied pieces and went to Cleaveland Tools and purchased  the already threaded blocks.  They still needed to be cut to  size but at least the threads were already done.

The tie down  blocks have been clecoed to the spar, holes match drilled,  nut plates  drilled and ready to be attached but first prepared the tie  downs for  primer and primed.  Nut plates were attached after the primer  dried.

The last step of the wing spar is to attach the tied down brackets  to  the spar and bold on the Aileron Bellcrank Brackets. All rivets are  in  and bolts torqued to specs.  On to the wing ribs.

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