Matt’s RV7 Build Log

I need to source a 1/4″ metal tube in order to drill the elevator horns. Time to search some builder websites.

Tasks Completed:

• Finished trimming HS skin to fit elevator counterbalance 

Tonight I got the horzontal stabilizer back out and began doing all the final assembly work before starting on the firewall. I am still going to wait to do the fiberglass till later.

Tasks Completed:

• Fit elevators to stab.
• Started trimming the stab skins to fit the

Tonight I was able to get the trim tab clecoed into position on the left elevator. I am within 1/32″ of the trailing and inboard edges which I am pleased with. It looks as if the travel needed will be within spec once I get the bottom of the trim tab bend to clear the rivets in the elevator.

Tasks Completed:

• Match drilled the forward hinge to the left elevator assembly
• Trimmed inboard edge of hinge

Tasks Completed:

• Washed, acetoned, etched and primed trim tab spar and horns
• Riveted bottom flange to trim tab skin
• Riveted horns to skin and spar

Note: A couple of the rivets for the horn did not seem to seat well. I will need to review with the tech counselor. Also getting everything dimpled and riveted together in the trim is a BITCH! I made a couple of cosmetic booboos to the skin trying to get dimple dies and a squeezer in there.

After reflecting over christmas I decided to go the way of many who have gone before me and order another trim tab skin. The deciding factor was a lack of clearance between the elevator and trim tab where they meet on the trailing edge. I didn’t mark my line for the outboard tab bend using the square so after the bends were made the edge clearance goes to nil as it goes aft.

On the bright side I decided to do this now to save from drilling rivets or ordering all the other trim trim tab parts. Once the skin arrived on Thursday I made quick work out of redoing the bendsm matchdrilling, and dimpling all the parts.

Tasks Completed:

• Ordered and prepped new trim tab skin
• Deburred and dimpled all trim tab parts
• Countersank E607 trim tab spar
• Finished installing screws for E714 

I started on the trim tab tonight, but quickly got into a little trouble. The wood break I made for bending the elevator skin tabs does not have interlocking top half. So when I tightened the C-clamps the inside half slipped out causing a slight kink in the trib tab skin. It’s minor and helps “customize” my -7 but after that I hung up my tools for the night.

Tasks Competed:

• Began riveting skin to skeleton
• Mark elevator tab for drilling
• Started working on trim tab 

Tasks Completed:

• Removed vinyl from inside skin
• Riveted counterbalance skin to 701 skin
• Clecoed skeleton to skin

A lot got done today on the left elevator. I went over to a friends shop to get a good cut on the oak I planned to use on the sking tabs and trim tabs. I marched through the riveting of the skeleton and even the tab bending went quicker than I tought it might. Even with the doublestick tape I had trouble keeping the very end of the wood inplace for the bend. Overall I am pleased with the results. I hope to improve my tab bending art when doing the trim tabs.

When riveting the skeleton I waited to rivet E713 and 714 together. Instead, I first riveted the inboard rib to the spar and then riveted the outboard rib to both of these. Getting to the rivets that mount the ribs to the spar is WAY easier with this method. I also replaced the original counterweight with a new one because I had cut the original down. Getting the holes to line up with the counterbalance skin holes and the ribs holes was a pain. I highly recommend not screwing this part up in the first place. With a little body english, I finally got the bolts to fit.

Tasks Completed:    

• Made new counterweight
• Dimpled left elevator skin
• Bent elevator skin tab
• Riveted left elevator skeleton

I just returned from a week in LA shooting a spot. I was wiped out but managed to spend an hour tweaking the right elevator leading edge bend a little more. It’s coming along although it proving to be harder to get a good edge bend as compared to the rudder skin. Most of the issue is that the top edge should overlap on top of the bottom edge. However, for whatever reason Van’s made the bottom half longer than the top. So I am fighting the edges to line up and create a nice edge once the two halves are mated.

Tasks Completed:    

• Continued leading edge bend on right elevator

Today I was going to prime the left side parts but decided to go ahead and complete the riveting on the right elevator. Everything worked out well. When I do the left side I will be waiting to rivet 704 and 703 together until I get the short rib to the spar thereby avoiding the squeezer gymnastics needed to get all the rivets squeezed in that joint.

There’s two items I need to investigate further. First, Van’s came out with the soft rivet bulletin this weekend. Although I am not affected by their apparent mishap, it got me thinking that I had bought some rivets locally early on before knowing the difference between soft and hard rivets. And, just tonight, it felt like a few of the rivets were VERY easy to squeeze. The other thing I need to check on is the quality of my trailing edge bend. It seems like it needs a little more massaging in the middle sections to reduce some bowing I see. Work is going to kill me over the next couple of weeks so I might not get a lot more done on the elevators in November.

Tasks Completed:    

• Finished riveting the right elevator skeleton
• Riveted 701 skin to right elevator skeleton