Matt’s RV7 Build Log

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.

–Match drilled E610P and E702
–Clecoed E703 and 704 together
–Matchdrilled them to E702
–Shaped E714 and clecoed E713 into place.

NOTE: E610PP holes don’t quit align with E702 holes.They appear to be 1/32″ off. I emailed Van’s. They said if I can get the clecos on without distorting the spar, then its probably ok to drill. Build on…2 hours

We just got back from a long weekend in Vegas. It was nice be in the warm desert before our winter really kicks into high gear. Now back to the project!

• Clecoed left elevator skeleton together
• Cut away right counterweight per plans

Note: Holes in the outboard right elevator spar doubler and the E701R spar are slightly off set by approx. 1/32″. I need to contact Van’s to confirm this is within tolerances. Update (11.20.07): Joe B. at Van’s says its no issue as long as no torsion is created in the spar by trying the force the clecoes in place (which is not happening in my case). Problem resolved.

–Continued Riveting rudder skin to skeleton

Tonight I worked on the the counterbalance skin and right side of the bottom rib and spar.

–Riveted stiffeners on the right skin
–Assembled rudder
–Match drilled skins and spars 

–Finished assembling rudder skeleton
–match drilled counterbalance skin
–match drilled ribs, rudder horn, and lower spar

I fixed the counterbalance skin fit problem by shaping the counterweight a little more and by starting the clecos from the front and working backwards.

–Riveted VS skin to skeleton
–Riveted rear spar to skin and skeleton 

–Riveted VS rear spar and skeleton

Note: Bad rivet on VS 707 to 702 caused bending in the rib flange. I don’t like the looks of it and need to fix.

–Finished HS riveting

Final HS Punch List:
–Check skin edge for proper deburring (completed: 3.23.07)
–Torque rear spar bolts (completed 3.23.07)
–Touch up nicked primer
–Check front spar rivet (completed: 3.23.07)
–Check rear spar rivet (completed: 3.23.07)
–Rivet front tips left and right (completed 3.23.07) 

–Finished riveting HS front spar
–Started final assembly of HS