Tonight I planned on completing Section 13 (Main Spars), therefore I clecoed the Tie-Down Brackets (W-1020) to the Spar Assembly (W-SPAR ASSY) and finished riveting them. Lastly I attached the Aileron Bellcrank Brackets (W-823PP) with the required hardware and torqued them down to 25in-lbs. Project 13 is now completed!!!
Today I started fabricating the Section 14 Angle (W-1029C) and Spacers (W-1029D & W-1029E) by cutting them on the band saw and sanding them on the belt sander. Once I got home, I immediately primed both Tie-Down Brackets (W-1020) and hung them up to dry. Next I cleaned the powder coating from the insides of the holes on the Aileron Bellcrank Brackets (W-823PP) using a #12 and 1/4” drill bit. Then my Dad helped me rivet the fuel tank and wing attach nutplates to the Spar Assembly (W-SPAR ASSY) and that was enough for tonight.
I started fabricating the Tie-Down Brackets (W-1020) today by cutting them to length on the vertical band saw at work during my break. Then my uncle helped me tap the ends to 3/8” X 16 X 1” DP. I took them home, filed the edges down, and drilled the required pilot hole. I clecoed them to the Spar Assembly (W-SPAR ASSY) and match-drilled all the required holes using #30 and #12 drill bits. Next I removed the Tie-Down Brackets, clecoed on the nutplates (K1000-3), and match-drilled the rivet holes using a #40 drill bit. Then I machined countersunk the aft side of the Tie-Down Brackets for the heads of the nutplate rivets and deburred all the holes.
I went ahead and scuffed and cleaned the Tie-Down Brackets with a green Scotchbrite pad and Lacquer Thinner. Next I rinsed them and then placed them in the Metal Prep solution for a few minutes. Afterwards I rinsed them off and submerged them in the Alodine for a few minutes. Finally I removed them, rinsed them off, and hung them up to dry. I plan on priming them tomorrow.
Tonight I began riveting the wing access plate attach nutplates to the Spar Assembly (W-SPAR ASSY) and then countersunk the screw holes so they could accept a dimpled 0.032” skin that a #6 flush head screw could fit into. For the left spar only, I enlarged the existing 9/32” hole to 3/8”. Afterwards Dad and I spot primed all the countersunk holes where the anodize finish had been removed. The next step had us run a #40 drill through all the 3/32” fuel tank and wing attach nutplate rivet holes in the web of the Spar Assembly. Then we ran a #30 drill through the three spar doubler to spar web rivet holes. We machined countersunk the nutplate attach holes and the three #30 holes. Finally we riveted the AN426AD4-6 rivets into the spar doubler to spar web holes.
After having to take some time off I was finally able to get back to work. However during my time off my Dad came down and deburred and spot primed all the holes that were countersunk. Now for tonight we were able to rivet the fuel tank skin attach nutplates to the Spar Assembly (W-SPAR ASSY). Afterwards we began countersinking the fuel tank attach screw holes in the spar so that they could accept a dimpled 0.032” skin that a #8 flush head screw could fit into.
Over the past few nights I have been diligently countersinking all the holes on the Spar Assembly (W-SPAR ASSY) and tonight I finally finished them all!!!!!
Tonight my brother came down and decided to help me out!!! I told him that the J-Stiffeners (W-1028A & B) needed to be match-drilled and showed him to follow the aft most rows of 3/32” holes in the Spar Assembly (W-SPAR ASSY). He sat down and went to work and was able to complete one and a half of the spar flanges before he had to leave. I finished the last half and then Dad came down later and finished up the other two sides while I deburred all the J-Stiffeners. Then he went back thru all the flanges and run a #40 drill through all the 3/32” holes of the Spar Assembly.
I started last night aligning a Long and Short J-Stiffener (W-1028A & B) to one of the flanges on the Spar Assembly. I used my calipers and set the edge of the J-Stiffeners 1/16” higher that the Spar Assembly flange as was shown. I then clamped them down and match-drilled a 3/32” hole into every fifth hole. This takes a lot of time by myself, so tonight I got some more help from my friend Michael. I lined up the edge, he clamped it down, I drilled the hole, and he would put a cleco in. We finished lining up the other three flanges before calling it a night. Next I will start match-drilling the rest of the holes in the J-Stiffeners.
Came home tonight and clecoed the Spar Splice Plates (W-1006E) and the Main Spar Web Extensions to the Spar Assembly (W-SPAR ASSY). My Dad came and gave me a hand with riveting them together using AN470AD4-5 rivets. We finished both wings and had some really nice looking rivets. I then moved on to the Short J-Stiffeners and cut them down to the specified length (53-3/4”) and then deburred all the edges.
I am back again for some more, and tonight I started off with priming all of the small alodined parts. I used Tempo Aviation Zinc Phosphate Primer that I picked up at Aircraft Spruce and when I started priming it kept splattering the paint. I tried shaking the can some more and even spayed it continuously on some cardboard to see if I could clear it. Nothing seemed to help, but these parts will not be seen anyway so I pressed on. However I also picked up some Dupli-Color Self-Etching Primer and used it on my ELT mount and this stuff was much better!!!
While those dried I jumped ahead and fabricated the two Tie-Down Brackets (W-1020) by cutting them to length and drilling the pilot hole. I will get my Uncle to tap (3/8 X 16 X 1” Deep) the ends tomorrow when I see him. The last thing I did was cut the Long J-Stiffeners to length (92-1/4”) and deburred the edges.
JerMo's RV-10 Project 