Ron's RV7 Aircraft Factory


Welcome to my personal blog. This site was created as an informal description of my build progress in the construction of a Van's RV7 aircraft. A place where family/friends/builders/curiosity seekers can follow along. It is not intended to be a detailed description of every step in the building process as that would be much too time consuming. There are plenty of sites that do a great job in that arena, that is not my intention with this site. My intention is for this to be a philisophical/motivational/inspirational account of the emotional ups and downs of the life changing journey...and it will change your life. I hope this will give you an idea, through my eyes, of what its like to make this transformation. A note to other builders, I am not an expert so do not put your safety at risk by attempting anything you see on this site until you have done your own research, or send me an email so we can discuss it. Any deviations from the plans are not approved, nor endorsed by Van's Aircraft or myself. Thanks for visiting.



Wednesday, June 15, 2011

Mountain Flying Lesson 1: Granby HOBBS 710.5 hrs

Last week I did my first flight over the 'rocks' in a GA aircraft. Lyn and I took the short flight up to Granby (GNB) and back to introduce me to mountain flying. We are kind of transitioning away from purely tailwheel training now to add some other stuff to the curriculum. So, mountain flying is now front and center in my aviation development. I've been reading Sparky's book to prep myself for this.

It was quite amazing at how easy and short the flight was compared to driving up there. I have a friend that has a cabin near there so I've drove it many times over my years of living in Denver. Even flying the relatively slow Citabria, we were up there and back in about an hour and a half. At least twice as fast as driving. And the scenery was great! I really enjoyed the perspective of seeing my beloved mountains from the cockpit. Gotta love the utility of general aviation.

Winds aloft were light, about 17kts at 12,000 ft, and amazingly turbulence wasn't a factor during our warm afternoon flight. We crossed Rollins (Corona) pass at about 13,000 ft to give us a little more than our desired 1,000 ft clearance above the ridge. Not much to it, just approach the ridge at a 45 degree angle so that you can easily turn away from the ridge if you experience downdrafts that exceed the performance of your aircraft. Once you have the ridge made--ie, you can glide to at least the top of the ridge with the engine at idle--you then turn perpendicular to the ridge to exit the area asap in a direct route away. The ridge crossings are where the winds will be strongest, heavy up and downdrafts can exist, so its not a place to loiter if you don't have to.

Because it was a relatively warm day, coupled with the extremes of our altitudes (over 50 peaks exceeding 14,000 ft in Colorado) here in the Rocky Mountains, I kept an eye on our performance as we flew. We easily maintained a 500fpm climb without much laboring of the aircraft. That's with two people, full fuel and a small survival kit I threw into the baggage compartment. Not bad for the 160hp engine we have under the cowl. I would prefer 180hp or more for this type of flying, but this will do. You just have to be more careful without extra HP in the mountains, it gives you fewer options to avoid trouble. One of the reasons I plan to put such a big engine (200+ HP) in my RV.


This shot, taken from the AOPA flight planner shows a direct route from Boulder to Granby. We didn't quite follow that route as we went slightly to the left to intercept the pass before proceeding into Granby. If you click on the photo and look closely, you can probably see where the pass is located, to get an idea where we crossed. This kind of route is typical, mountain flying here is not usually done in straight lines...you are usually following the lower terrain. 

GNB sits at about 8,200 ft MSL and the pattern is flown at 9,000...at only 800 ft AGL, its a little less than the usual 1,000 AGL I am used to flying patterns at. Different sight picture, but no big deal beyond that.

We landed to the west on runway 27, which is the preferred runway because of rising terrain on the departure end of runway 9. Density altitude was 10,400 ft when I checked it during my preflight. I overflew the runway at midfield and entered the right hand pattern for 27.

Being uncomfortable with a new airport pattern and Lyn chirping in my ear on base to watch the rising terrain I mentioned earlier, I came in a little high and fast on final. I tentatively did a forward slip to shed some of it but still floated and landed long. Not a great effort on my part with the landing...the learning process continues. Because of this, I had to back-taxi halfway down the runway, before we lined up on 27 and took off for the return flight to Boulder.


I have to say, now that I've done it, it didn't seem nearly as treacherous as I was expecting. Flying in the mountains, despite the terrain, is nothing to shy away from in my opinion. Lyn instructed me, as all good pilots should, to always be on the lookout for places to set her down in the event of an engine failure. On this particular route, there were very few times there wasn't an open field within gliding distance. Of course, it might be a dicy landing, but should be one we could walk away from...that's what matters.

Our next planned flight is up to Lake County airport (LXV) in Leadville. Its perched at 9,927 ft MSL and I believe it is the highest elevation GA airport in the US. It is kind of a right of passage to land there and snap a picture so I am pretty stoked to add my name to that list.

Saturday I am attending the Colorado Pilots Association Mountain Flying Ground School. It is an all day class and it gets good reviews from everyone who takes it. I figured this would be a great way to complement my flying activities with some classroom learning. It should be fun, I love this kind of stuff.

Wednesday, June 8, 2011

Mid Fuselage HOBBS 710.5 hrs

With the aft fuse done, I'm now officially chugging away on the mid fuselage. As you might guess, this is essentially the cockpit area of the fuse. The spar carry through is included in this sub-assembly.


Starting to cleco it all together. I had to move the aft fuse assembly off the sawhorses and put it on a pad on the floor. As these large assemblies go together, the garage is getting smaller all the time! :) When I start attaching fuse sections together, I will need to rearrange and organize the shop better. Notice some of the seat ribs are already primed...these were 'filler' parts--when I had extra primer from previous batches. Don't want to waste that stuff if possible so I try to have extra parts ready for primer in case I have extra.


Four of the seat ribs get this modification...add a 1-1/2in diameter clearance hole and then remove the material (seen in the next shots). I used my hole cutter...as much as I hate that thing, these were a piece of cake to do...not nearly as bad as the tank access holes (remember those?).


Area to be removed...I just used my die grinder and a cutoff wheel to finish this up...easy peazy! Looked nice and professional when I was done with a file, emory cloth and scotchbrite. By now, you should be an ol' pro at stuff like this.


Two of these four seat ribs also get some additional modification. This is a 'removable' cross section that I had to fabricate. It will be attached with screws to the rib. This is needed so you can get the stick control arm in place.



Coming together...the rear area is the floor of the baggage compartment.



If you look close at these last two shots (click to enlarge), you will see how you have to notch both the seat ribs and the baggage ribs around the grommets for clearance.

Tuesday, June 7, 2011

Exuma Pics HOBBS 708.5 hrs

Just a couple shots of the group in Exuma...cool stuff! You can certainly tell I am awfully jealous of my friends right now. ;)

Rosales photo

A couple of RV's in trail formation on final approach into Pittstown I think?

Tanya Card photo

Ol' Scotty in the lead in 339A...


Tanya Card photo
This has to be the best photo I've seen from this trip! This is Rosie in a nice steep banked turn over a picturesque lighthouse. Look at the color of that water! :)

Aft Fuselage Riveted HOBBS 708.5 hrs

Well, I was able to finish up the riveting of the aft fuselage...solo! Amazingly enough, I found a way to get it done by myself with some clever thinking. Not that I don't like good RV builder company and I had offers...just that its so much easier to knock it out by yourself if you can. People are busy...have lives, etc, so its a hassle to try and coordinate those things sometimes.

Anyhow, it was really cool to see that big ol' assembly finished up! Certainly stepped back, smiled and admired my work after this while sipping on a cold beer. :)

For other builders that may want to try this solo, it really wasn't too bad once I figured out my strategy. I didn't think I was going to be able to pull it off...and then while standing back scratching my head, looking at it with a cocked head like a confused dog, I had a 'light bulb' moment.

This was my strategy...

1. Do the bottom rivets on each bulkhead to the bottom skin...I had one side skin off while doing this for better access.
2. Next, cleco both side skins and small aft tailcone in place.
3. Rivet the small aft tailcone to the bottom skin
4. Rivet the side skins up to the top J-stringer...no further. These are pretty easy to do.
5. Rivet the small aft tailcone to the side skins
6. Now it starts getting tricky moving to the bottom skin. Do the side skin/bottom skin seam on the forward portion up to the first bulkhead. It takes some long arms to get the last ones...I could barely reach them but you could back-rivet them if you cant quite reach.
7. The middle section-side skin to bottom skin is the difficult one. I used my back rivet set in the gun and my tungsten bucking bar to do these. Rivet gun, obviously on the inside, bucking bar acting as a back-rivet plate on the outside. This is a little blind on some of them...and an advanced riveting technique so be careful. Take it slow and be methodical--no hurry. Pretty easy once you get in a rhythm though. I was happy with the results.

Here are some pics....


Riveting away on the side skins...FAA shots. :)



I went back and forth on this dang bottom J-stringer. Should I put it on top of the small aft tailcone bottom skin? or under it? I'm not sure anyone else had as much agony over this decision as I checked other builders sites. :) I finally decided to go on top of the bottom skin...it does cause a small gap between the J-stringer and the side skin where it transitions but once you rivet it tight, its hardly noticeable. She'll fly.


Here is my fix for mistakenly putting a nut plate in there for the Adel clamp that will hold the rudder cable. For some reason I thought the Adel clamp went on the outside of the fuse?? Duh...not! Anyway, I fabricated two pieces of sheet alum and riveted them in place for some added strength for the attachment point. They are rattle can primed which is why they are dark gray.


Look at that nice smooth riveted surface....woooooweee, nice huh?



Bottom skin to side skin...first rivets are set by reaching from the front. You can see where the cleco's are still in place...that's as far as I could reach.



Now, you can see the results of back-riveting that final section in the center.


And voila...a finished (at least up to this point before we install longerons) aft fuselage!! Riveting things together is always the best part of the build.

Thursday, June 2, 2011

Rum and Coke? HOBBS 703.5 hrs


Scott and Deb and the gang have all arrived safely for their week's stay in the tropics. Check out Scott and Tanya Card's pics from the trip over. Gorgeous shots, including a couple really nice ones of Scott and Deb in 339A...if that doesn't get you stoked to be an aircraft owner, I'm not sure what will?? These kind of trip reports really help to justify the time I spend slaving away on this plane. I can't wait to join in on the fun. As Scott said in his post on VAF..."it is all SO worth it...I need to get back to my Rum and Coke mon!"

Deb Mills photo
Scott and Tanya Card (photo by Deb Mills)

Wednesday, June 1, 2011

Aft Fuse Ready to Rivet HOBBS 703.5 hrs

Over the holiday weekend, I canceled plans to go to the mountains and do some fishing as the weather didn't look too promising for such an endeavor. Soooo...I spent the weekend with the mistress instead. Remember, holiday weekends are not for having fun...but getting extra work done on the plane! ;) I gotta get a life.

Anyhow, I made some good progress. The aft fuselage was completely prepped and now its cleco-ed back together...next step is riveting. I already finished up the far aft assembly and the tail spring.

As you can see, I am now over 700 hrs in the project. I've come a long way...with a long way to go in this journey. As I look back, its really amazing how different of a builder I am now compared to when I started, you really do learn a lot when building one of these.




I ordered a Dynon pitch servo mounting kit from Aircraft Spruce. $75 for this thing, what a ripoff--its just a simple alum bracket and some misc hardware. Ah, such is life in the aviation business, everything costs more than it does in the real world. ;) While I was at it, I also stocked up on some torque seal and drill bits.


Tail spring drilled, mounted and finalized. As you can see I primed the very aft tail cone bottom skin. I figured this is an area that would very susceptible to water entry and pooling. I know, I know...my plane might be so heavy it will never fly when its done!! But it wont corrode. haha



Bottom side view of the tail spring. The large hole is a wrench access hole for the attachment bolt (not shown). You also have to make that funky cutout (Vans gives you a pattern to follow) for the tail spring mount.


A lot of guys have complained about the bottom skins directly behind the baggage compartment 'oil canning' in flight because of airflow in that area. More of a nuisance than anything, but I didn't want my airplane making funky noises if I can easily fix it. I have heard of guys going to elaborate measures (laminated stiffeners, etc) to solve this problem. I was originally planning to just add some kind of homemade stiffeners in that area. Then it dawned on me that I had some extra J-stiffener material left over. I checked the plans and couldn't see a need for them later, so voila...I used them to stiffen the skins. Looks very professional...I like it. Hopefully that solves the problem. I was able to back rivet these which was nice. 

Edit 07/06/11: Jason Beaver mentioned to me that some guys were experiencing cracking when installing skin stiffeners in the tail cone. The general concensus on VAF was to tie them into the bulkheads so they wont flex as much. I'm not sure how, or if, I am going to modify mine but think about this before you do yours.



Riveted the elevator bell crank together...this is where the servo motor will attach later.


This is the $75 bracket (after priming...it comes as bare alum) from Dynon and their installation instructions.


And here it is, riveted in place. That's all I need for now, the $750 servo motor will be installed later when I win the lottery and have the money to buy it. ;)


Here are my added J-stiffeners back riveted in place.





Since I painted the aft bottom skin, I stayed consistent and did the aft side skins also. Ignore the nut plate for the rudder cable that I added. Stupid mistake...I didn't read the plans correctly. I removed those later and just dimpled the hole for a #8 flathead screw. An adel clamp will be used here to secure the rudder cables as they exit the fuse.

Open Water HOBBS 689.0 hrs

Progress check...Scott and Deb and the gang are, as I write this, over open water!! I've never flown over open water like this yet in my flying career, I would think it would be very interesting to say the least. :) Dont forget you can click on the pic to enlarge it for a better view.