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  #1  
Old 06-27-2016, 03:51 PM
PilotjohnS PilotjohnS is offline
 
Join Date: Jan 2016
Location: Southwest
Posts: 1,811
Default RV-9A, pilotjohns

Well the fun begins. Took the $50000 free test flight this morning and have a RV9 tail kit in the car, heading back to Los Angeles.

Been dreaming of building since i was 17.

Plan is for cross country machine io320 high altitude cruiser. G3X glass. Basic and simple.


What I built before from scratch; no plans, no nothing except a skillsaw, a makita drill and a bunch of homemade jigs. (and the wife gone for two weeks)

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John S

WARNING! Information presented in this post is my opinion. All users of info have sole responsibility for determining accuracy or suitability for their use.

Dues paid 2021, worth every penny

RV9A- Status:
95% done, 10% left to go
Electrical/Panel done
Firewall Forward 75%done
Fiberglass 0%, thought i was building in metal?
www.pilotjohnsrv9.blogspot.com

Last edited by PilotjohnS : 06-09-2019 at 10:18 PM.
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  #2  
Old 06-27-2016, 04:22 PM
Dbro172's Avatar
Dbro172 Dbro172 is offline
 
Join Date: Apr 2012
Location: West Fargo, ND
Posts: 1,076
Default

That's awesome John, Good Luck with the build.
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EAA Tech Counselor
RV-9A #92103 - N803DK
G3X, Superior XO-320, Dual Pmags, Catto 3B
www.mykitlog.com/dbro172/

1974 Bellanca Super Viking - N16AW - Flying
RV-8 #83565 - N184DK - building
1968 Mooney M20C - N6801N - Sold
1956 C-182 - N744W - Sold
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  #3  
Old 06-27-2016, 05:42 PM
scard's Avatar
scard scard is offline
 
Join Date: Jun 2005
Location: Cedar Park, TX
Posts: 3,368
Default

Good luck. It WILL change your life if you stick with it. Just imagine, before long you won't think twice about heading across the country at 13.5k' sucking on a little O2 with the autopilot set, eating a sandwich and watching the world go by.

I'm still trying to unlock the mystery of why a subway sandwich above 12k' tastes so darn good.

Let me introduce you to your neighbor and my good buddy Rosie. You should be just in time for 2019...
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CQ Headset by Card Machine Works
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RV-9A N4822C flying 2200+hrs. / Cedar Park, TX
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  #4  
Old 06-27-2016, 05:50 PM
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Vlad Vlad is offline
 
Join Date: Oct 2008
Location: Utah
Posts: 8,440
Default We are all ears

Welcome John nice to have you here.

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Не имей сто рублей, а имей сто друзей.
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  #5  
Old 08-08-2016, 08:49 PM
dwranda dwranda is offline
 
Join Date: Jan 2015
Location: Jamestown,NY
Posts: 657
Default

You should be just in time for 2019...[/quote]
If I may ask, is there something happening in 2019 that I need to make sure my plane is done for? That would be a good goal!!
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  #6  
Old 08-10-2016, 05:32 PM
PilotjohnS PilotjohnS is offline
 
Join Date: Jan 2016
Location: Southwest
Posts: 1,811
Default 2019

I think 2019 refers to the next Rosie Grand Tour.

Thanks all for the advice. This site is wonderful and I think that this is the most important tool.
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John S

WARNING! Information presented in this post is my opinion. All users of info have sole responsibility for determining accuracy or suitability for their use.

Dues paid 2021, worth every penny

RV9A- Status:
95% done, 10% left to go
Electrical/Panel done
Firewall Forward 75%done
Fiberglass 0%, thought i was building in metal?
www.pilotjohnsrv9.blogspot.com
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  #7  
Old 08-26-2016, 10:55 PM
PilotjohnS PilotjohnS is offline
 
Join Date: Jan 2016
Location: Southwest
Posts: 1,811
Default Progress

So I am making progress on the sample wing section practice kit from Vans. This practice kit uses all the tools so is very helpful in getting to know my way around cleco pliers and such.

A word about reamers and drill bits; the holes in the parts are prepunched on a very precise CNC machine so everything lines up. If things don't line up, something is wrong. I found the clecos from Brown Tools are professional grade and line up the holes precisely. The prepunched holes are slightly undersized and need to be enlarged to final size. This can be done with a standard drill bit or a reamer bit. The reamer looks like a drill bit but the flutes are straight up and down. I use the reamer just like a drill bit and enlarge the holes to final size. The reamer produces a nice clean hole that is perfectly round and others say less prone to cracking; reamers also tend to leave smaller burrs so deburring seems to be minimal.

Deburring was a challenge. Most of the tools I tried for deburring the holes were too aggressive. I found what works best was a 120 degree counter sink on the end of a tapped rod. And for the skin edges, the old tried and true butterfly deburring tool works great (red handle on bench). For drilling out bad rivets, the drill press was invaluable. I can lock the piece down to the table and use an end mill to knock off the head. It turns out the heads of a squeezed rivet are pretty hard and it is easy to bugger the flight piece if not careful. All the more reason to make the rivets right the first time, quality is never having to say rework. I also made a holder for the clecos. This was suggested by a mechanic friend and was a great idea.

I thought I would get away without having a belt sander, then I realize the reinforcing strips of the practice kit didn't fit without heavy mods. I tried to trim with snips and files, but was not happy with the results, so I broke down and bought a belt sander and added it to my lazy Susan in the background. What a difference. I also tried to rivet with the DRDT2 in the foreground and that was hopeless; there was no way to secure the part and operate the handle while keeping everything aligned. My best rivets were with the Cleveland Main Squeeze shown in the corner of the bench; what a nice tool. I used the close edge dimpling tool attached to the bench in the corner with the rivet gun to dimple the ribs; this was noisy and brutal. The results were good, but it is still too out of control for my liking. So next time I will either use the Main Squeeze or I will make a top guide for the rivet tool to keep everything lined up. The less I rely on my holding things straight, the better the results seem to be. Jigs are our friends.

Also, having the work well secured seems to make it much easier to add a little English to the tools to keep everything lined up as the rivets are formed.

I feel confident that the skills I have tested on this kit are good enough for real parts. Next up this weekend is the riveting the skins to the spars and completing the practice kit, and then having my mechanic friends review and critique.

So I am making progress. Who needs sleep, there is plenty of time to sleep when I am not building.

__________________
John S

WARNING! Information presented in this post is my opinion. All users of info have sole responsibility for determining accuracy or suitability for their use.

Dues paid 2021, worth every penny

RV9A- Status:
95% done, 10% left to go
Electrical/Panel done
Firewall Forward 75%done
Fiberglass 0%, thought i was building in metal?
www.pilotjohnsrv9.blogspot.com

Last edited by PilotjohnS : 08-26-2016 at 11:01 PM.
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  #8  
Old 06-27-2016, 07:23 PM
bruceh's Avatar
bruceh bruceh is offline
 
Join Date: Mar 2008
Location: Ramona, CA
Posts: 2,509
Default

Quote:
Originally Posted by PilotjohnS View Post
Well the fun begins. Took the $50000 free test flight this morning and have a RV9 tailkit in the car, heading back to Los Angeles.

Been dreaming of building since i was 17.

Plan is for cross country machine io320 high altitude cruiser. G3X glass. Basic and simple.
$50,000? HA! Hope you have more than that.

I'd be happy to give you a motivation flight any time. I'm down in SD.
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RV-9A N5771H flown over 900 hours!
http://www.overthehills.com/RV-9A-Project
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  #9  
Old 06-27-2016, 09:21 PM
PilotjohnS PilotjohnS is offline
 
Join Date: Jan 2016
Location: Southwest
Posts: 1,811
Talking Thanks

Thanks everyone for the words of encouragement. Bruce I just might take you up on your offer. And Vald, you are my motivator with all your stories.
On my bucket list is a flight to Puerto Rico, so.....

Derek and Scott, Hope you don't mind a few questions in the future; it is great to have people like you in this community.
__________________
John S

WARNING! Information presented in this post is my opinion. All users of info have sole responsibility for determining accuracy or suitability for their use.

Dues paid 2021, worth every penny

RV9A- Status:
95% done, 10% left to go
Electrical/Panel done
Firewall Forward 75%done
Fiberglass 0%, thought i was building in metal?
www.pilotjohnsrv9.blogspot.com

Last edited by PilotjohnS : 06-28-2016 at 10:18 PM.
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  #10  
Old 06-28-2016, 10:33 PM
PilotjohnS PilotjohnS is offline
 
Join Date: Jan 2016
Location: Southwest
Posts: 1,811
Default Added pictures

Hi all I just added pictures to first post
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John S

WARNING! Information presented in this post is my opinion. All users of info have sole responsibility for determining accuracy or suitability for their use.

Dues paid 2021, worth every penny

RV9A- Status:
95% done, 10% left to go
Electrical/Panel done
Firewall Forward 75%done
Fiberglass 0%, thought i was building in metal?
www.pilotjohnsrv9.blogspot.com
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