Dave’s RV-7A Building Log

I used WishZone.com to give some hints for good presents for my birthday this year. My parents sprang for the Emergency Locator Transponder, and my in-laws bought the com and transponder antenna. Very nice.

Julie (with a little guidance from me) found a great present. There’s a local guy, Bruce Williams, that owns an Extra 300L and does aerobatic training. Julie bought me a spin & recovery training package. Bruce has his plane up here in Seattle only during the summers. In May I’ll be able to do the training. I’m really looking forward to it.

I also ordered the Airflow Performance fuel pump and filter kit from Van’s a few days ago, which coincidentally arrived today. This pump is only required for a fuel injected engine, which is what I’m planning on using. It looks like a pretty straight-forward assembly (as with most of Van’s stuff) with some tricky tube bending. It wasn’t absolutely necessary to get this kit right now, but I wanted the parts to finish the cabin covers. The pump and filter look very cool. I guess they should for how much the things cost.

Worked just a little bit more on the electric aileron trim. I drilled holes for the platenuts and then deburred and cleaned all of the parts that I’m going to prime.

I looked back at what I was doing on my birthday last year. I was just starting to work on the fuel tanks. I’ve gotten a long way in a year. And the project has gotten much more fun and challenging.

I again today spent more time on house projects than on the plane. We’re trying to put in a patio in the back yard before summer. That’s taking precedence right now over the plane.

I did manage to work on the electric aileron trim a little bit. I drilled holes in the plate to attach it to the seat ribs and to attach the plastic block to it.

The instructions for the electric aileron trim remind me of the empennage kit. They’re step-by-step and very explicit. I guess I’ve gotten accustomed to the lack of detail in the fuselage instructions. Having such clear instructions has been refreshing.

I didn’t do too much on the project today (for a Saturday). I studying the sections ahead in the instructions and plans to see what’s left for the fuselage. The fuel and brake lines look like they’re going to be tricky. The electric aileron trim looks like a good thing to work on next.

I pulled out the plastic block for the electric aileron trim. I drilled the holes and did the other modifications necessary for the block.

Didn’t do too much today, as we had plans to go out for dinner. I just riveted on some platenuts to the forward cabin cover.

I received an order from Cleaveland. I went back and forth several times on whether to use real static ports or the cheesy pop rivets that Van’s supplies. I ended up just spending the $20 and buying the ports. They look very nice and should be easy to install.

The flap actuator calls for safety wiring in one spot, so I bought pliers and two different sizes of safety wire. I played around with the pliers a bit. They’re very easy to use and make a nice looking twist.

As is typical for this project, the second time through is always easier. I’ve been dreading fitting the right gear mount after the back-breaking ordeal with the first one. Well, I got it done in under two hours. I even had time to finish doing the taxes!

I didn’t even bother testing the fit until I enlarged the bottom skin hole to nearly match the left side. It only took 2 iterations after that to get the hole perfect. I also ground down the mount in just 2 passes to clear the one rivet that interferes. I had a little bit of interference between the gear mount and the lower longeron, but it was able to squeeze by. I put in 4 bolts, tightened them down, and drilled the holes. I even managed to countersink the forward mount holes on both sides for the flush #8 screws.

The first picture shows how the leg of the mount won’t fit through quite yet. I marked where some trimming was needed, pulled out the mount, trimmed with a sanding drum in the Dremel, and tried it again. The second picture shows the mount installed. And the third picture shows a close-up of the troublesome rivet.

I’m very glad the mounts are now fitted. Once I get the fuel lines figured out, I can mount them permanently.

I deburred the two covers for the flap actuator and deburred the forward center cover. I riveted in the heat baffle and started the process of attaching plate nuts.

Still not feeling well, so I just reviewed the instructions for the upcoming tasks. I’m not going to mate the wings at this point. I just don’t have enough room in the garage, and I don’t want to leave the garage door open for any extended period. From what I’ve heard, it’s OK to wait until later to mount the wings. I’ll still run the fuel lines. I’ll just leave extra tubing on the outside and trim it to fit once the wings are in place.

I read the steps for fitting the empennage parts to the fuselage. It doesn’t sound too complicated. I’ll try that once I get a few more things done in the cabin.

I ended up taking a sick day today as I was feeling horrible. I tinkered with the project a little, but didn’t do anything strenuous. I deburred the flap actuator channels and then riveted the parts together and installed plate nuts. Everything can be squeezed, if you do it in the right order. I ended up riveting the bracket on one end too soon, so I had to shoot 3 of the rivets holding one of the angles on. No big deal.