Daily Archives: May 27, 2013


Elevators 11 (4.0 hrs)

I started out today by bending the elevators.  I was much more careful bending them this time to avoid the errors of bending the rudder.  The bends came out perfect! 20130527-204920.jpg

On a side note, here is my new vertical stab holder I built.  I plan to expand on this and hang the rudder there as well.  I’m trying to plan ahead now that the wings are within sight…. despite not being ordered.20130527-204941.jpg

20130527-205008.jpg

Final drilling the spar reinforcement plates.20130527-205016.jpg

The counterweight skin and rib.  This was a collasal pain in the butt.  The counterweight skin did not match the holes in the two adjoined ribs.  After consulting Van’s Airforce archives, I found that this is a common issue.  Some people recommended just drilling the holes out resulting in slightly imperfect or oblong holes.  With the added stress of the counterweight I did not want to reduce the strength with less than perfect holes.  The holes on the ribs were wider than on the counterweight skin.  In order to reduce that distance the radius between the flange and the web of the ribs needed to be reduced.  20130527-205023.jpg

20130527-205029.jpg

I used the dead blow hammer to reduce the web-flange radius.  This took quite a bit of trial and error but eventually worked.  Another trick here is to cleco the skin in place without the counterweight.  After all the clecos are installed, then shove the counterweight in between.  The entire process took some finesse but eventually I had all the holes lined up and every cleco properly seated. 20130527-205036.jpg

20130527-205045.jpg

Some pictures from the final skeleton.  Next step will be to cleco the skins and begin final drilling…20130527-205101.jpg

20130527-205158.jpg

20130527-205205.jpg


Rudder 15 Complete (almost!) (1.5 hrs)

Today was the completion of the rudder leading edge.  I made a mistake in bending the lower section first, inhibiting my pipe’s access to the upper portion.  The result is a very clean looking lower half, with a less tidy upper half.  Its not beautiful, but its functional and airworthy, and I’m moderately happy with it.  20130527-204554.jpg

20130527-204604.jpg

20130527-204620.jpg

20130527-204627.jpg

20130527-204636.jpg

Here you can see a couple ripples from poor bending technique on my part in the upper part of the rudder.  Still looks pretty good, I think.20130527-204657.jpg

My wife and the completed rudder.  (Actually its not complete… I still need to do the front two rivets on both of the ribs and one corner rivet that I cannot currently access)20130527-204712.jpg


I met Mike at the airport on Saturday evening to pick up some rivets to replace the brittle rivets I’ve been having issues with.  Mike was excited to fly as the winds had been high all day and they were finally within limits.  He asked me if I wanted to go… like I was going to say no!  We took a quick flight up over Codorus State Park, and it was a great opportunity to explore some more of the RV-7 flying characteristics.  One word: WOW!  Mike demonstrated aileron rolls, which were quick and crisp.  I took the controls and flew over the lake pointing out a few of the places I was familiar with from when I worked at the marina.  We easily were pulling 3-4 g’s in the steep turns.  I hadn’t seen the RV series do stalls before, so I asked Mike to demonstrate the stall performance in the RV.  It has a very crisp and sharp stall.  The power on stall was the most impressive.  It was hard to get it to stall, as it just kept climbing like a beast!  I was seriously impressed with the climb performance demonstrated… it was truly hanging from the prop!  Finally I took back the controls and asked Mike if he wanted to learn a new aerobatic maneuver.  He wanted to make sure I knew what I was doing first (can’t blame him!)  The wingover is a very gentle and benign maneuver with very little chance of stall or overspeed.  I demonstrated 2 or 3 times and gave the plane back to Mike.  He had it mastered in no time.  He’s looking to take aerobatic instruction soon.  I believe his fun factor in the 7 will reach a new level after that.

Afterwards, we went for beers a Johannson’s down under… at this point I could feel it had been awhile since I had flown, and even longer since I’d done any aero… I couldn’t believe it.  I was a little air sick!  I was embarrassed and pissed at myself for allowing myself to be out of the air for so long that a few gentle maneuvers managed to make me a little woozy!

Regardless, the RV-7 is a fantastic flyer, and I cannot wait to have my own (8 that is)!