Rudi's RV10 Build: RV ZULU-X

[Dan Geib]

Hello Rudi,
I stumbled upon your site today and read through each posting of your RV10 build. I am impressed with the workmanship that you have exhibited through out the build process. I would like to build an RV10 myself. I am currently building a 3 car garage that I am planning to use as my shop. Keep up the excellent work! Looking forward to reading about your prgress this week.
Regards,
Dan

[RudiGreyling]

Hello Rudi,
I stumbled upon your site today and read through each posting of your RV10 build. I am impressed with the workmanship that you have exhibited through out the build process. I would like to build an RV10 myself. I am currently building a 3 car garage that I am planning to use as my shop. Keep up the excellent work! Looking forward to reading about your prgress this week.
Regards,
Dan

Great DAN! that is why I post it, to inspire people just like you to do it!

[RudiGreyling]

Good Morning RVators,
[Week 60 Hours = TBA]

This was a short week, due to EAA Margate convention over the long weekend.
Rosie riveter recovered from her flu and the rivet gun got an overhaul so its working again so we finished riveting the last fuselage skin to the cabin top. See picture below of rear tail cone skin in place


We drilled the windscreen to place and made the final adjustments for fitting, including the little tabs to hold in place along the bottom edge.


De-Mark the glue joint and scuff it up nicely to get a rough texture for better bite.


I decided to paint my dash, now was a good time before glueing in the windscreen. Knowing I wasn't going be home on the weekend (EAA Margate) and having a day job means one resort to funny things to paint late at night.


The dash came out pretty well, it is the same textured paint I used for the interior door frames and window close outs.


Then the windscreen got glued in for good.


That is where I left it before setting of for Margate for the weekend. This week I need to make the fairing between the windscreen and the fuselage.

Till next week,
Groete
Rudi

[mkmuirhead]

Looking good Rudi. Thanks for the update...it is a highlight of every Monday!

[RudiGreyling]

Good Morning RVators,
[Week 61 Hours = TBA]

Another slow week, been busy helping others
viewtopic.php?p=771320#p771320

I did manage to fit my roll protection bar and swivel map reading lights that can also focus on the panel if required


Hope to make some progress on fitting the doors this week.

Till next week,
Groete
Rudi

[RudiGreyling]

Good Morning RVators,
[Week 62 Hours = 762]

This week I managed to do my regular amount of work on the RV10. It was all about fitting the door closing mechanisms to the door. I don’t like Van’s add-on safety latch, so I bought a third party safety latch that works together with the main handle…more on that later

The door lever mechanism being drilled to the door


Here is the door closing pins and the middle (third party) safety latch. It requires you to modify the long rear pin and then this middle gearbox fits in the middle of the door and operates the cam you see in the picture to safety close the door mid way


Here is the new middle gearbox, you need to make a cut-out in the door like so…


So it can fit like this…


With the 3rd party kit you also get new improved exit blocks, so your exit pins can travel further in and out. The rear pin blocks shaped to fit and pin exit hole drilled in the door, note the pin travel guide extension inside the door.


In position…


Same for the forward blocks…


In position


Then you can fit all the pins and gears into the door, making sure you have enough exit hole clearance for the pins and gears. Below you can see a assembly picture of the lever, gear and pin mechanism before it is closed up.


Here is everything assembled, with the door lever in the OPEN position. The cam has not been installed on the middle gearbox yet, it will be done with the door in assembly on the aircraft.


Here is the same door in the CLOSED position. See you get a 180 degree throw on the lever and cam. Note the locking pins now extend out the front, also the rear not shown.


The next 2 pictures show the exterior Door Handle up close…


And afar…note the locking pin sticking out the door front


Now with both door closing mechanism installed I need to fit these doors to the fuse again and drill the corresponding pin closing holes in the fuselage. We will see how good these fit this week.

Till next week,
Groete
Rudi

[RudiGreyling]

PS: I also saw i just crossed my anticipated 1/2 way mark i.e. 750 hours (I estimate it will take 1500 hours for a quick build RV10) It is all downhill from here...

[Jan]

Did you say downhill
Not so sure.
The third party safety lock looks good

[crazeeflya]

Did you say downhill
Not so sure.
The third party safety lock looks good

....the last 10% takes 90% of the time!!

Up to your usual standard and looking good, Rudi!

[minivan]

Hi Rudi

every time I look at your progress it looks like you are going downhill - coasting along and just picking up speed every time!!!

Looks great so far, and I like that 3rd party door lock.

Enjoy the journey

Pierre

[Hugo Stark]

Lyk mooi Rudi

Grte
Hugo

[Hotdog]

Baie mooi Rudi! Your effort with the fibreglass has paid off and I can't wait to see how it all comes together.

[RudiGreyling]

Good Monday Morning RVators,
[Week 63 Hours = TBA]

This week I managed to do a little bit again, becuase I am helping out with RV12 again.

The doors are hinged back onto the fuselage cabin to drill to lockin mechanism into the cabin frame. Below is the center latch and cam in the OPEN position, jou can see the cam clearing the locking block.


Then the door in the CLOSE position, you can see the cam closing and latching the door in the middle, what you can see is the fore and aft pins extending into the cabin frame locking the door fore, middle and aft into position.


Next up I installed my McMaster door rubbers. Once again an aftermarket product that is better than the Vans standard issue door seals.


I took good care to mark the required door seal gap when I initially fitted the doors to the cabin , here the seal is 1/2 round the door frame.


My doors closed with the rubbers installed without the need to do any additional trimming...Whew!


This week I need to install the GAS strut to keep the door open.

Till next week Monday,
Groete
Rudi

[Jan]

Die pienk ystervark kom nou mooi aan

[RudiGreyling]

Good Monday Morning RVators,
[Week 64 Hours = 779]

A Slow week because I had some R&R at Barberton Bush Fly In. I managed to fit the gas struts to the doors.

First you make a wooden spacer the length of a closed gass strut, to posistion the gas strut brackets on the door.


Drill and rivet the brackets in place on the door


Compress Gass Strut and fit temporary to door


Viola! Open Sesame!


A nice good even lift


Now these doors need to come off, strip them and get them ready for paint...

Till next week Monday,
Groete
Rudi