Riveting the lower firewall attach angle, routing the brakelines, and starting seat pan #2

July 31, 2012

Tonight I spent an hour or so routing the brake lines from the firewall bulkhead fitting down the gear leg and then into the brake caliper. Since I don’t have my brake calipers installed (still trying to figure out these Matco wheels) I only flared the top fitting, but I routed the bottom close to where the caliper input will be. After that I debured the 1/8″ holes on the lower firewall angles and firewall itself and squeezed those rivets. I also installed both #8 nut plates on the inside angles to hold the exhaust channel. After that I started working on the second attempt at a seat pan. The first one just didn’t fit well as I screwed up the 3/4″ roll around the tube (no quite square to the seat) so it never fit right and the straw that broke the camel’s back was that when I drilled through for the scews it was so tight that I couldn’t get the seat back on and there was no 1/2″ to 1″ sag so I just scrapped it and started over no big deal its just sheet metal. Anyway I transfered the dimension off the drawing to new piece of sheet metal and rough cut it with the sheer but it was getting late and I needed some dinner.

Time spent today 3 hours
Total Time spent 1521 hours


Routing the fuel drain line, engine ground

July 31, 2012

Today I spent a good chunk of the day doing some relatively seemingly simple tasks of routing the fuel drain line. I didn’t want to waste any more 5052 tube so I decided to get the route good with my 3003 tube that is really flexible first then match it with the tube bender. First thing was first though, before I left for the airport I welded the 1/8″ NPT union to the attachment plate for the drain pet cock and the staight flare fitting at the bottom of the fuel drain tube. Once I got to the airport I counter sunk and bucked the nut plates that hold the plate to the bottom belly pan. After all that was done i was able to get an idea on how the routing was going to end up. I used the versa tube (3003-0) to get my routing right and I matched pretty quickly. I then flared both sides and installed the tube.

After that I had my wife help me route and secure my engine ground wire. I have a ground wire that comes off one of the four studs that would be where a prop governor would go if I had one. I have a 4 gauge wire that go to one of the mouning bolts for the inverted oil valve which acts like a ground lug. On the back side (inside the cockpit) I have more 4 gauge wire that runs all the way back to the battery. This way the battery has a non frame ground attachment to the starter. The only wires that ground to be frame are master switch and the oil pressure and temp gauges. If the ground isn’t good enough I will route a ground wire to the ground lug and attach it there. But I’m betting it will be plenty good.

I also finished up drilling the final holes for the rivets of the 3/4″ angle on the bottom side of the firewall so that I can finish the forward belly pan. Those rivits just need to be installed and that area is finished up.

Time spent today 6 hour
Total time spent 1518 hours


Matco wheels and brakes and fuel vent line and drain line

July 26, 2012

Today I recieved my Matco Wheels and brakes. I went with the WE-51L which are 6.5 pounds each and are goo looking. Dimensionally I new they may pose a dimensional issue as they are slightly smaller than the standard clevland 40-78 wheels. The first issue is the brake plate to wheel hub on the vans brake plate is only 3/4″ when you add in the standard 1/4″ spacer it come to 1″. This wheel needs about 1.4″ so I will have to add to the vans brake plate/spacer by 3/8″ because I want to keep the 1/4″ thick spacer so that would bring it out to 1.388 inchs on the brake plate to axle spacing. All the vans brake plate tube is is a 1 3/8 0.058 4130 tube. So I have a little work to do to get them to fit.

I also routed the fuel tank vent line and drilled a hole in the forward belly panel and installed a grommet. I used my polyurethane tubing for half of the vent line so that I avoid making a bunch of complicated bends and routing lines. I also did some bends to route the fuel drain line and now I need to weld on the union fitting to a plate install the nut plates drill the hole through the forward belly panel and screw it in place.

Time spent 4 hours
Total time spent 1512 hours


Riveting the forward belly pan torquing and safety wiring the prop

July 22, 2012

two day roll up on sunday I spent quite a bit of time working on the belly pan by drilling holes for the rivets continued fitting and shaping until I was happy. I then dimpled out the rivet holes and hand bucked all the rivets. I also installed 4 nut plates to attach the firewall to the belly. On tuesday I brought out the right wheel pant and fairing so that I could check the intersection fairings I bought from Vans. I don’t think they will fit and I may send them back. The problem is they arn’t made very will and will need quite a bit of work to make them ready for paint and I just don’t see how the gear leg fairing will be correctly angled in to the airflow when the intersection fairing is smoothly laying on the wheel pant. It may be because they are shaped for the RV 6 and 7 and the sweep angle of the gear may be different. After that I trimmed the left kick panel slightly so that the pitot static lines will go through. And finally I torqued the prop to 40 then 50 and finally 60 ft-lb in accordance with the twisted composites paper work. After they were torqued I safety wired the prop bolts.

Time spent 10 hours
Total time spent 1508 hours


Baffle trim, fit and install

July 21, 2012

Today I spent a really long time working on the rear baffles. I started off by measuring how much of the baffle I would need to trim off. I measured marked and then trimmed the excess off the baffle. I then put the cowling up temporarily to check and I saw that I need to trim more. Once I got it the correct height I spent some time cleaning up the edges and drilling holes for the overlap screws. After I got everything cleaned up and de-burred I shot some rivets to connect them. I also installed some nut plates in the overlap area. I drilled and trimmed the ignition lead plastic grommets holes and ran the ignition leads through them. I then drilled all the holes for the screws that hold the silicone baffle seal to the baffle. I then installed everything including the safety wire that ties the bottom pieces together. After all that I installed the prop. It still needs to be torqued and safety wired so I’ll do that tomorrow.

Time spent today 8 hours
Total time spent 1498 hours


Checking the fit of the ailerons and slaves struts, weighing out the counter balance

July 21, 2012

I brought the ailerons out the the airport to weigh out the counter balance weight. I installed all four and leveled the aircraft poured the counter balance weight into the cup and hung it from the leading edge. I found that the lower ailerons need about 0.75 lb of leading edge weight and the upper ailerons need about 0.8 lb with the slave strut installed.

Time spent 2 hours
Total Time spent 1492 hours


Belly pan fitting and misc nuts bolts and cotter pins

July 17, 2012

Tonight I spent several hours fitting the belly pan that I haven’t finished yet. I hadn’t checked the fit since I put the engine back on and I needed to cut out a part of it to fit around the gear leg. I also spent some time finishing up the flying wires by fairing them and then tightening the jam nut and installing the cotter pins. I also installed the second jam nut on the wing side of the wire. Finally I installed the torque tube aileron drive bolt.

Time spent 3 hours
Total time spent 1490 hours


Rigging the wing Part 2

July 16, 2012

Well with much reluctance I decided I wanted to adjust the AOI on the right upper and lower wing tips so that they are exactly the same as the roots. To do this I had to detension the wires. So I detensioned the wires but I ran into a bit of a snag litterally. Even though I had sprayed Molyibdenum Di-sulfide on all the wire threads I had one of the landing wire and clevis gall on me while removing them. I had to cut off the clevis and about 1/2″ to 3/4″ of wire. It looked as though I had enough wire left to tension them up again (I had plenty after it was all said and done). So this time I put wheel grease over the moly disulfide as a extra lubricant. This seemed to work better but I still think if I had to de-tension them again I will try something else some kind of combination/concoction. Steen puts some sort of black grease type substance and those wires are so smooth. Anyway after several hours of messing with that wire I finally got around to putting two AN960 washers unt the top wing leading edge spar an the lower right wing leading edge spar and then retensioned wires. Since I had so many problems with the wires I just started from scratch on the rig. This time I have 1.5 deg AOI at the root and tips of each lower wings and at the center section and tips of the upper wing. This combined with absoulutly no dihedral or anhedral in the upper with and 0.8 deg dihedral in the lower wings and wires are all tensioned to 750 lb. I have what I now deem a perfect rig. We’ll see how it flys then make adjustments after that.

Time spent tonight 4 hours
Total time spent 1487 hours


Rigging the wings and tensioning the flying and landing wires

July 15, 2012

Today I spent most of the afternoon rigging the wings and tensioning the flying and landing wires. I re-leveled the fuselage laterally and longitudinally at the cockpit longerons. I then leveled the upper wing and started tightening the landing wires to bring the upper wing to fully level with no anhedral or dihedral. I used my three livingston wing rigging boards one on the center section and one on each tip of the upper wing to check for anhedral and dihedral. If all three board tops line up there is none. I then started incrementally tightening the flying wires and landing wires to such that the tension came up but the wings didn’t move. I got the landing wires up to 750 lb measured this using my tensionmeter from Holloyway engineering. http://www.radialengine.com . The flying wires a a tad less tension since the geometery is more favorable, but both are between 650 and 750 lb as per the S-1S maintenence manual. I then checked my Angle of Incidence (AOI) to see where I was. The upper wing center section was right at 1.5 deg which is to be expected since I checked this when I rigged the wings before covering. The left upper wing tip was at 1.5 deg which is perfect and the left lower wing tip was at 1.5 deg along with the both lower wing roots. The right upper wing tip was at 1.0 deg and the right lower wing tip was at 2.0 so I’m off by 0.5 deg there or about 0.160″ or 2 AN960 and 1 AN960L washer if I do my geometry correctly. Unfortuanatlly the lower right wing tip is at too much AOI and the upper right tip is at to few so I have to de-tension to added the washers under both front spars. I tried very hard to get this just perfect during welding but I guess I just didn’t quite get there I was off by about 5/32″ boo hoo. So tomorrow I will de-tension and add those washers in and re-tension to see where I am no big deal.

Time spent today 6 hours
Total time spent 1483 hours


Attaching the Flying wires, tightening the bolt and nuts

July 12, 2012

Several day round up. After Eve and I got the wings mounted I was able to get all the flying wires routed and clevis and nuts installed. The next day I was able to get elevator trim cable routed and installed, even though it was a pain in the ass i got it done. I then worked on installing the new clevis’s on the tail wires. I figured it would be logical to get the tail rigged and wires tightened. I used my digital level to level the aircraft then i leveled the tail and tighten the wires. I made sure the tail stayed at 0.0 degs to match the longerons. I also installed the stabilizer support tube. Finally I installed the new 1/2″ spacer block and three bolts to finish off the elevators. I also spent some time checking the AOI on the wings to see where I was on the wings after tightening the bolts. I may have to make a small adjustment to he right wing lower wing AOI but we’ll see once I get the wings rigged.

Time spent 8 hours
Total time spent 1477 hours