Dave’s RV-7A Building Log

Finished wiring up the #$@% capacitive plates. It’s not fun trying to get the connectors on the inboard plate, but I finally got it.

Got the flaring tool back, so I’m working on the tank again. I flared the vent line (remembering the sleeve and nut this time) and worked on installing the capactive plates.

Started putting the capactive plates and fuel vent line in the right tank. Then I noticed that my flaring tool is still loaned out. I guess I won’t be finishing this tank until I get that back.

Deburred the rear baffle.

Cold ProSeal is my new friend. After asking on the RV7 group, the consensus was to chill the ProSeal but not mess with the hardener ratio. I kept the ProSeal tube in the fridge right up until I needed it. It was slightly harder to mix, but not as bad as I thought it was going to be. I also kept a bucket of ice water nearby and dunked the whole gun in that while I was riveting. Worked like a charm. I had 1.5 hours working time and probably could have gone at least another half hour. It also helped that the shop was 10 degrees cooler. That at least made it much more pleasant for us.

With Julie’s help I sealed and riveted in the last three interior ribs in the right tank and smeared ProSeal on the shop heads, including the ones I couldn’t do from the last session. I also had enough time and ProSeal to do the anti-rotation bracket for the fuel pick-up. I could have even done more stuff, but didn’t have anything else ready to go.

This tank is well over half way done. That’s a good feeling.

Second sealing session done with Julie’s help. Riveted in two ribs. I was hoping to get three done, but the sealant started setting up after just 45 minutes. This is the first tube of the next batch that I ordered. It seems to be setting up much faster. It’s also 80F in the shop. I’m sure that’s not helping. For the next session, I think I’ll try not mixing in all of the hardener and/or putting the sealant gun in some ice water to keep it cool.

Julie pointed out the odd coincidence that we always seem to be ProSealing on special occasions, my birthday, Mother’s Day, and now Father’s Day. What better way to celebrate a special occasion, eh?

Completed the first sealant session on the right tank. I back-riveted on the stiffeners, back-riveted the filler flange (with better luck than with the other tank), squeezed on the drain flange, and attached the tooling hole cover and nose reinforcement to the outboard rib. Pretty productive session.

I also dabbed some sealant through the filler hole on the left tank to try to cure the slow leak. Made kind of a mess of it, but it’s all inside. Nobody will see it. Hopefully that took care of the leak.

It ended up being 80F by the end of the session. If this keeps up, I’m going to need an air conditioner for the garage.

The plan was to do the first session on the right tank after work. I washed the last of the miscellaneous parts and the ribs. Scuffed the remaining parts (filler flange, drain flange, etc.). Cleaned everything with MEK, including the rivets. Put down electrical tape where I didn’t want sealant. Got all of the tools ready. By the time all of that was done, it was dinner time. It’s amazing how long the prep takes, even when I think I have everything ready.

After dinner, Julie wanted to go to Home Depot. After that, it was getting too late. Plus it was still 80 in the garage. It’s been way too hot here the past few days.

Not much progress lately. Lots of end of school year stuff and a soccer game and swim meet, etc.

I did manage to scuff up the sealing surfaces on the right tank ribs.

Did just a short session. Riveted the access cover reinforcement ring and plate nuts for the right fuel tank. Didn’t use sealant for this on the other tank, so didn’t use it here either. The instructions say it isn’t necessary, and I agree with that.

At this point, I just have to scuff the ribs and deburr and scuff the baffle. Then everything is ready to go for this tank. I just have to find 2-3 hour blocks of time for doing ProSeal. Might be tough this week. Lots of other stuff going on. At least all of the parts are organized and ready to go.

Did a ton of work on the right fuel tank today. Deburred and dimpled the rest of the tank ribs. Trimmed and deburred the capacitive plates and attached nut plates to them. I had screwed up one of the coax connectors on the other tank, so I ordered another one a week ago for this tank. I soldered that to a piece of wire. I attached the other wire to the outboard capacitive plate.

Drilled, deburred, and countersunk the drain and fuel cap ring.

Drilled and deburred the access plate and reinforcement ring. Dimpled the rib and countersunk the access ring. Dimpled the skin and deburred the edge. I used the C-frame to dimple the #8 screw holes. We’ll see if that helps the skin sit more flush. Scuffed the inside of the skin where things are attached. Scuffed the stiffeners.

I was hoping to do the first ProSeal session today, but realized that I’m out of time and energy. I thought at least the tanks were completely ready to go. And then I noticed the baffle sitting in the corner. Still need to debur that. At least I won’t need it for a while.

Tons of parts almost ready to go.

Goofy self-portrait from the photographer.