TitleGarrison

No bird ever flew nonstop from New York to Tokyo, or raced 15 miles high at triple the speed of sound.                                                                                                   
  But birds do something else.
  They do not conquer the air; they romance it.
.”

  Peter Garrison

HoursAndCounting

Jur's RV7 Aircraft Factory
2917 hours
and counting
Some decisions in life are bare of any obvious logic

 

 Started countersinking the main spar. For some reason, everytime I have to take material away from the main wing spar, it gives me the creeps.

The countersinking is required because the spar flanges are 0.063 thick and this is too thick to dimple.
Everywhere the skin touches the spar, the holes need to be machine countersunk.

First I determined how deep the countersink needed to be. This is always difficult. I made the following 2 shots to give you an idea how it should look like.
On most pages they say, countersink until the rivets fits perfectly flush and then go 2 clicks under. But this is according to me not always enough.
I always make a small test plate the same gauge as the skin and then make a 3/32 dimpled hole. I used the c-frame to dimple it as to have the same shape as the skins.

I then rivetted the small plate on the spar and you see that the plate lays perfectly flat.

You have to do this test rivetting because the dimple will still reshape a bit when you rivet it in. Even when a dimple doesn't  perfectly make the plate lay square to the spar, sometimes after rivetting it will pull in.
I drilled the rivet out and used the test plate rivetted side of to test measure my new countersinks.

Verify the depth often. As the countersink cage sets after some holes and the tool warms up, the depth will vary and you will start to go deeper and deeper. You will have to return 1 or 2 clicks after doing some 30 countersinks. That's normal.

As usual, verify that the holes are nice and round and concentric. No bumps in the countersink, you want nice and smooth surface.

Some shots :

To change ideas, I also dimpled the wing walk doublers and the remaining wing skins of the left wing

They are all finished now. 

Smooth ! Right wing is done, left wing is half done. One more side to go in the next work session.

In the meanwhile, my replacement parts for the fuel tank baffle have arrived so I may switch back to fuel tank work this weekend.

How to use

Use the kit buttons in the top ribbon bar to see a chronological overview per sub section per kit. For the full chronological article list, see chronological build link in prelude menu here below. The easiest way to lookup information is by typing in some part numbers or keywords using the search option in the ribbon bar

 

Caution !

Some advice on reading my log for fellow builders !

In some articles, I made corrections at later date on the original article to rectify my own stupidities or faults. Read through the entire article if you intend to use my findings/experiences on your own project !

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It’s possible (not likely) that I’m not as smart as I think I am. (Occasionally, I have moments when I know this to be true. Fortunately, the feeling passes quickly.) Although I have tried to make this information as accurate as I can, it is not only possible, but also quite likely, that erroneous and misguided information lurks within these pages. I cannot and do not warrant these pages to be error free and correct. Furthermore, I accept no liability for the use of this (mis)information. And, as many would say, your mileage may vary. If, after reading this, you are intent on proceeding, please be aware that the contents of this site are protected by copyright (copyright © 2011 and 2012). Nonetheless, you may copy this material subject to these two conditions: (1) any information used is for non-commercial purposes, and (2) the source of the material is properly credited. Of course, you may link to any page herein. At some articles, snippets of the plans from Vans are visible. These are for educational and illustrations purposes only and should never be used as plans for part construction or assembly as plans may have changed since the picture was taken and more important they are protected by Copyright by the Vans Aircraft Mothership company.

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