Rudi's RV7 build progress...Done and Flying

Ed · Unread post by Ed » Tue Nov 15, 2005 4:30 pm

Keep posting, Rudi, I wanna see it all

RudiGreyling · Unread post by **RudiGreyling** » Mon Nov 21, 2005 7:45 am

Good morning my fellow RVators,

It's been a good week!

"Look Ma no Clecko's!"

I manage to finish riveting the leading edge. My wife (a.k.a) "Rosie Riveter" helped and did the best riveting to date. The LE does not have a scratch on the outside...hmmm if she keeps this up i might just choose to build a shiny RV and not paint it at all!

I used a nifty "Alodine Pen" on the insides of the skins where the ribs go. I did not want to prime the skins, since they are already ALCLAD protected, but you do get scratches where the ribs fit etc. The Alodine Pen creates a chemical reaction, discolours the aluminium, and corrosion prove it.

I took the whole wing apart, disheartening after seeing it together

, and started to final prep and debur the wing skeletons. I had to countersink 194 holes x four sides almost 800 holes on the main spars for the wing rivets to sit flush...I feel like a CNC machine man

Here is a picture of the spars, click on the link for a bigger version; all those little shiny holes are precision countersunk. Can you say "Wide Angle Lense Photo"?

http://www.RudiGreyling.com/pictures/rv ... r_2048.jpg

Till next time, Brrrrrrrrt
Rudi

RudiGreyling · Unread post by **RudiGreyling** » Fri Nov 25, 2005 8:26 am

Got my inspection visit from my friendly neighbourhood AP (approved person) last night. He inspected every single rivet outside and inside, while I hold thumbs and

. He passed it without a single failure...JIPPIE! $\:D/$ Thanx mr AP. Now I can continue and close those Leading Edges up.

AndyCAP · Unread post by **AndyCAP** » Fri Nov 25, 2005 4:24 pm

Hi Rudi

thanks for keeping us in the loop! To watch a master builder at work is truely inspiring! I was really impressed by your website too (check it out for those of you who have not seen it yet!!) I'm totally baffled as to how/where you find the time do do all of this!

I am still currently on RC stuff and am very excited about your tip on using Isoboard (might contact you sometime about it). In the Loooo..ng term I would also love to build something like an RV - just dont know if i will be able to keep my garage as neat as yours

keep up the good work!

RV · Unread post by RV » Sat Nov 26, 2005 7:52 am

Jeez Rudi, a masterpiece is being born.

I love the tone developing in your posts, the excitement is building up.

What a beaut.

Regards

RV

RudiGreyling · Unread post by **RudiGreyling** » Mon Nov 28, 2005 9:15 am

Good morning my fellow RVators,

Firstly, thanks for the kind comments

AndyCAP wrote: <SNIP> I was really impressed by your website too (check it out for those of you who have not seen it yet!!) I'm totally baffled as to how/where you find the time do all of this! <SNIP>

Andy, Luckily I am a Computer Keyboard Jockey by day...so my website gets updated during my launch time etc at my day time job. I try do something on the RV every evening for 1-2 hours, and spend the other 1-2 hours with the family as well. It is all about a delicate balance.

Back to the RV...I riveted the Leading Edges to the Spar...Boy oh Boy it was very difficulty to do the main rivets that hold the LE ribs to spar

. This is a well known area on the RV7 that could have been designed a bit better by Vans for bucking rivets. Some guys just fit pop rivets since it is not really structural, but my wife 'Rosie Riveter' did a great job and we fitted the solid rivets.

The rest of the LE rivets along the spar were made easy work with my trusty pneumatic squeezer.

Next I am suppose to finish the tanks, but I dread working with Proseal (Black Death) to seal the tanks so I am going to finish the top wing skins first.

Till Next Time,
Rudi

RudiGreyling · Unread post by **RudiGreyling** » Wed Nov 30, 2005 7:32 am

Good morning my fellow RVators,

I liked this view, so I thought I'd share it with you guys..."Can you say Pin cushion?”

RudiGreyling · Unread post by **RudiGreyling** » Mon Dec 05, 2005 8:57 am

Good Morning fellow RVators,

Abra Ka Dabra, Siem Sala Biem! POOOF!...No more Cleckos on the wing top skin! $\:D/$
If it was only that easy...

'Rosy Riveter' did a Fantastic job again!

Started working on tanks again, first take these long angle alu angle and make some stiffeners for the bottom of the tank. It reinforces the bottoms of the tank where all the weight of the fuel sit, and maybe it helps prevent a bit of fuel slosh.

Cut them to right shape and length.

Polish, debur and round the edges.

Clecko, and match drill to the bottom of the tank.

Till next time,
Rudi

Jan · Unread post by **Jan** » Mon Dec 05, 2005 9:11 am

Hi Rudi,
Now you are getting closer to the messy stuff! Don't forget the little flapper door in side the tank.

RudiGreyling · Unread post by **RudiGreyling** » Mon Dec 05, 2005 9:31 am

Jan wrote:Hi Rudi,
Now you are getting closer to the messy stuff! Don't forget the little flapper door in side the tank.

Hi Jan, Ja, Black Death a.k.a Pro Seal tank sealent.

RudiGreyling · Mon Dec 12, 2005 11:32 am

Good morning RVators,

did not get as much done as I wanted to last week, since the Xmas parties this time of year side tracked me 3 times last week.

I finished the tank attachment angles; you manufacture these from aluminium angle; and it attaches the fuel tanks to the fuselage.

I drilled the fuel tank cap and drain valve flange.

In addition I have done a whole bunch of boring work, deburring and preparing for the big sealing sessions over the next couple of weeks.

Till next time,
Rudi

RudiGreyling · Wed Dec 21, 2005 12:14 pm

Good day RVators,

Lots of little things got done this week.

Prepping all the tank fittings and odds and ends:

Getting ready for the big proseal operation..

Getting ready to seal the stiffeners, the black tape ensures the area for ribs are kept clean until they need to go into place.

And the messy dreaded proseal job starts...here the stiffeners is in place.

A close up of the 'mess', this sucker is not going to leak!

Over the next week I have to finish sealing the tanks..Yuck what a messy sticky job. This is my least favourite job so far building the plane.

Till next time,
Rudi

RudiGreyling · Sat Dec 31, 2005 12:40 pm

Hi Rvators,

Well it was a busy two weeks, and Yippee my tanks are done. It took longer than I imagined and it is a k@k job. I hate pro-seal, but at least it is done.

Here are some photos:

The tank assembled in the cradle before pro-sealing the ribs:

The ribs, sealed in, see the black line along the insides of the ribs and skin.

The fuel sender and float with the standard fuel pickup

The fuel sender travel adjusted to be correct inside the tanks

My flop tube installation and tank vent line + vapour return line modification

The trap door to keep fuel in the first bay during rapid manoeuvres. The anti-hang up brackets for the flop tube, to ensure the tube does not get stuck during any aircraft attitude.

The final result:

It feels good, I am glad the pro-sealing is over. Looking forward to the next stage. Now cross your fingers while it cures for the next week, then I will test for leaks next weekend.

Till next time.

Kind Regards
Rudi

ClikkaClikka · Unread post by **ClikkaClikka** » Mon Jan 02, 2006 9:25 pm

Nice job. I am sure it won't leak.

papa-g · Unread post by **papa-g** » Tue Jan 03, 2006 8:51 am

Wow !! - that is great work....

Rudi's RV7 build progress...Done and Flying

Yippe, the tanks are done