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, September 26, 2012

Summer Ends/Fall Begins HOBBS 1538.5 hrs


As pilots, we all know summer is typically our prime time flying season...although I would argue that Fall and Winter are pretty darn good here in Colorado as well. With Summer 2012 now officially over, I like to look back at what I accomplished these past few months.

Last year, as you might remember, I was busy getting my TW endorsement and a mountain flying checkout...I had a blast with that as Lyn and I buzzed around in the Citabria. A year later, I now have roughly 30 hrs of TW time and have loved every minute of it. This Summer was as good or better than last summer, learning to fly aerobatics with Dagmar in the Pitts was, off the charts, fun! Not too shabby of a life, I have to admit, I am fortunate.

Of course, along the way, I made good progress on the build as I am now comfortably over 1500 hrs on the HOBBS project meter and I can see the light at the end of the tunnel finally. I am now well into the last year of the build and am slowly starting to get ready for the big move to the hangar in a couple months. Its crazy to think how far I have come in the last 3 1/2 yrs.


As I mentioned in a previous post...in tribute to the arrival of Fall, last weekend, I jumped on the motorcycle and headed for the big rocks to the west of Denver...sometimes called the Rocky Mountains. It was prime time for the fall colors and it was a glorious 75 degrees with not a cloud in the sky. Aaaah, I love this state. I did a scenic route, a 170 mile loop...Boulder-Nederland-Estes Park-Lyons-Boulder...along the "Peak-to-Peak" highway. As you can see it was nothing short of breathtaking...what a great day and a nice break from the project. Sometimes we need to get away from the build and remember there is another life out there...its not all about the airplane. ;)


Just past a big sign that said, "Do not stop on the side of the Highway" I find this scene. haha! I cant blame them for ignoring the sign and stopping...as I did too...it was just too hard to drive on by without snapping some pics.






I had such a good time on this ride, that I am going to head up to Estes Park again this weekend and stay a night in a hotel, go for a hike and enjoy the fall colors one more time. It will be my farewell to Summer 2012 and hello to Autumn....

SJ Plenum/Baffles HOBBS 1538.5 hrs

Almost all of my activity last week was focused on the Sam James (SJ) plenum and baffles. I am using the baffle kit supplied by Van's...and mating that with the plenum, you will need both. Let me start by saying, if you're like me and thought going with a plenum will save you a lot of time and headache versus going with regular baffles...you'll be sadly mistaken. Both routes take some time and iteration...and are kind of a pain. I cant say which is worse...but this plenum is kind of a pain in the rear to be honest.

Not to bash a vendor, but I've got to be honest for your benefit regarding my assessment of the plenum. I've met Sam James at Oshkosh and he is a real nice guy, but this plenum is not what it should be. The fit and overall quality are not on par with what I paid for it. The cowl was much better and I was very happy with that purchase, this one, not so much. I realized, I could've made my own...but it would've taken me a fair amount of time to get it just right...which lengthens my "time to flight". At this point, paying a little extra $$ to get flying sooner is worth it. So I will grin and bear it at this point.


First thing you will notice when you dig into this is that the Van's baffles will need quite a bit of material trimmed away from it. They are much bigger than they need to be. Here you can see several trim lines as I get ready to start cutting. I will say I agonized over this...am I doing this right? Finally I remembered that Chad Jensen had done a SJ plenum on his -7 and did a real nice writeup...so of course, I read through his posts and felt better about what I was about to do as it was the same as he had done. A sanity check is always worth a million! I spend more time head scratching and thinking about things than actually working sometimes! :)


So trimming/cutting commences...a little at a time. In between multiple fit checks with the plenum and top cowl so I knew I had enough clearance while maximizing the airspace under the plenum. You will get real good at getting your cowl on and off during this phase.



As I trimmed, I noticed that these angle support pieces had to go...dangit, wish I would have known that when I built them. I drilled out the rivets and removed them.


Its getting real close here...gives you an idea about what it should look like. I have a fair amount of glass work to do on the front and rear, but its getting there.


This big ol' honkin' gap is typical...what most guys do is cut this area and then re-glass it back into place to close it up. I'll post pics later to show what I mean.


I also had this gap on the rear that aggravated me...I don't think Chad has this problem so I'm not sure what happened here. That rear baffle position is dictated by the pre-fabbed support bracket that attaches to the engine so I don't know how I could've went wrong? It is what it is, long story short, I will need to do some glass work to close this gap up.



Front baffles/air dam will require you to trim off quite a large portion since its not needed with the plenum...here is what mine looked like. Pic below is what it looks like before trimming...


Monday, September 24, 2012

CAD Newsletter HOBBS 1538.5 hrs


I subscribe to the Classic Aero Designs (CAD) email newsletter so I can keep up on whats going on...new offerings, etc. I got my newest version over the weekend...and low and behold, my seats are highlighted in the seat gallery notice on the left. Cool!

In other news, great fall weather and fall colors here in the Rocky Mountains...love this state and this time of year. I took the motorcycle for a scenic loop from Boulder to Nederland to Estes Park via the Peak-to-Peak highway on Saturday. What a great ride and amazing fall colors! I didn't want to return from Estes Park...I actually was going to spontaneously grab a hotel for the night, but alas, everything was booked...apparently I wasn't the only one with that idea? :)

Oh...and by the way, I also did some work on the plane too...plenum/baffle work mostly...pics and descriptions to follow. I hope you had a great weekend!

Friday, September 21, 2012

Daydreaming About Brazil HOBBS 1526.5 hrs

On the VAF forum, there is a thread about a gentleman that is delivering an RV7 to a customer in Brazil. He departed Georgia, via Florida, Dominican Republic, Puerto Rico and eventually down the West Indies Islands to Brazil. I love to see trips like this...#1, it shows just how amazing it is to have an airplane like an RV...and #2, it feeds my adventurous spirit to daydream about someday doing a trip like this in an airplane that I built. On my "bucket list" is a trip very similar to this...from previous travels to South and Central America and even living in Panama as a 12 yr old, I absolutely love that part of the world. The geography, the warm weather, the food, the people and the culture resonate with me. To explore it in Wablosa would be a dream.

I am so busy with my own life and this blog, I rarely read other blogs...but one I do follow when I get a free moment is called Windtraveler...I can't remember how I stumbled across it, but it is very good, insightful writing...and wow, they are living an adventure that has always fascinated me and I enjoy living vicariously through them...living aboard a sailboat and giving the middle finger to corporate America. Brittany recently wrote a very good post about chasing your dreams that I enjoyed, give it a read...I am firmly on board with her sentiment. Always have a dream in front of you...life is much too short not to pursue your dreams, whatever they may be.

In that vein, here is one of my dreams...check out this route (superimposed on the SPoT track of the gentleman that is currently flying to Brazil). Not sure how much vacation time I would need or how expensive this trip would be...but those details will not clutter my dream, for now at least. One day I hope to pull this off.

What are your dreams? The only wrong answer is, "I dont have any"...


Thursday, September 20, 2012

Trudging Along HOBBS 1526.5 hrs

I frequently talk about the ups and downs of going through the build process...the inevitable peaks and valleys if you will. Right now, for whatever reason, I feel like I am trudging along...not really a good reason behind it, just chalk it up to part of the long process. But its important to keep at it during times like these...although my last couple weeks haven't been very productive, I am still grinding it out....one foot in front of the other, up the mountain to the summit. The enthusiasm will turn, in the meantime, progress is being made, that's crucial.


So, anyhow, here are some pics of finishing up the hose routing for the oil/air separator. This is mil spec 6000-12 hose I am using. You can see it took some creative routing to come out of the top of the engine, around my oil filter and over to the separator. I'm a little concerned that I have violated the bend radius of my hose...it looks ok as is, but I will keep an eye on it to see if it wants to collapse during normal engine compartment thermal abuse. If it does, I will have to try something different since this routing is the ONLY option for this setup.

Notice the two adel clamps holding it in place and away from the firewall. I don't want the hose to rub on the firewall, which is why I have two clamps in that area. Also notice, I am using high temp, stainless steel, adel clamps in the engine compartment...easily identified by the white silicone (vs black).


Now for the breather tube exiting the separator. Out of the tank it is the same 6000 hose, but then I cut up the alum breather tube that came with the FWF kit from Van's. Notice the two extra breather holes I added...


From my research you can tackle this one of two ways. Have the breather tube come down right above the hot exhaust, with the idea that the oil will just burn off. Or have it actually exit the cowl, like I have chosen to do. I read that this is the way it "should" be so that you have a low pressure suction force to draw the oil out of the tank, which makes sense to me. I've been told that this system works so well with typical RV aerobatics that there wont be much, if any, oil coming out the tube. If I'm wrong, I figure I can always change it later if I don't like this setup...for now, this is it. I thought about this a lot...too much really, sometimes you just need to make a decision and move on.


Here you can see my routing from the tank out the bottom of the cowl...adel clamps...etc


I talked earlier about my desire to safety EVERYTHING in the FWF area. Here you can see I have added safety wire to the hose clamps, which I am doing everywhere...just makes me feel better.


I attached my lower exhaust pipes as indicated in the exhaust installation hand sketches...and was proud of this pic, looks nice. I then did a fit check with my cowl and found out that the exhaust pipes were too wide in this configuration and would not clear the bottom cowl! dang! I am in the process of getting this fixed right now...tweaking it.

Also notice the two holes I drilled in the breather tube that I mentioned earlier. This is a fail safe, in case the end of the breather tube gets plugged (icing maybe?) for whatever reason. You want the engine to be able to breathe, and these holes in the warm engine compartment should allow for a secondary path to do just that. Also notice my positioning of them...I don't want oil dripping out of there while its sitting in the hangar, hence I didn't put them on the bottom.


Things are starting to get tight in the engine compartment...its gonna get worse as I add wiring, cables and SCAT tubing, etc.


Installing the heater muff. You would think this would be straightforward wouldn't you? Not so much if you've never done one...or seen one. I didnt realize the cable clamps held it all together. The instructions from Mr. Vetterman are pretty poor. Finally got it worked out though...and then thought, duh! It really is simple...


And there ya go...now you know what it should look like. :) I ended up repositioning the cable clamp screws up next to the inlet/outlet later.


Back to the seats...I drilled a hole for a rubber grommet for wire routing of the heated seats.

Monday, September 17, 2012

Renegades Video HOBBS 1516.0 hrs


Friend and fellow RV7 builder Sean Thomas shot most of this footage and Jim Gray produced this nice video of the Rocky Mountain Renegades (all RV's except for a Giles 202 flown by Steve Bergevin) performing during our airshow last month. The video, and the flight demonstration, were very well done...nice job guys!


Monday, September 10, 2012

Competition vs. Airshow Pilots HOBBS 1516.0 hrs

Dagmar sent me this humorous video, its about a year and half old, but its the first time I've seen it. Cracks me up! Beware...adult language.


Half Raven HOBBS 1516.0 hrs

I decided to go with a "Half Raven" system on Wablosa. Its called a half raven vs. a full raven, simply because you are only installing about half of a full inverted flight system. Essentially it is just the air/oil separator tank for a cost of ~$400 vs. well over $1000 for a full inverted system. Raven makes a good product for less $$ than the Christen system...nice quality too, I was very happy with this hardware. The tank is more than just a oil holding tank...there is a large ball check valve inside the tank, check out Raven's website for drawings that illustrate how the system works.

What does a half raven system get you? In the simplest of terms, it will allow momentary (few seconds) zero or negative G maneuvers without dumping huge amounts of oil overboard onto your belly through the breather tube. This should be plenty sufficient for the type of flying I plan to do in the -7. I always say, if I want to do more serious aerobatics (and I might), I will rent or borrow a Pitts or Decathlon with a full inverted system.

I used this excellent post by Paul Dye as my installation guide. Again, another great example of guys 'paying it forward'...taking the time to do a detailed explanation of an install for the benefit of builders coming behind them. Thanks Paul.


Tank mounted and starting to run my 6000-12 rubber hose. There are three connections on the tank...top one goes to the engine breather tube outlet, middle one goes down to the exhaust for oil discharge and the bottom one goes to the oil sump.


It took some creative routing of the hose to connect the tank to the engine breather outlet...going around my 90 deg oil filter adapter.


Since I will use my Pmags for tachometer readings, I needed to cover the mechanical tachometer port on the engine since I wouldn't be using it. Doing some research I found that Andair makes a cap for this...bought it through ACS. Not much to it, alum cap with an interior O-ring and holes for safety wire. As I do my FWF work, I am a fanatic about safety wiring EVERYTHING, above and beyond what is required on certified aircraft even...more on this later, but I am glad the cap had this capability built into it.


Here you can see it safety wired in place just to the left of the oil filter adapter.


And in typical Ron Duren fashion...I am bouncing all around with my tasks...here I am back on the panel, I have mounted my audio panel and radio's in place on the panel.


Back to the cowl fitting and installation. I still had the bottom cowl side and bottom hinges to install. Rivet and flox...same deal as before. I replaced the alum hinges on the bottom with SS versions. This is an area that is prone to cracking due to the high vibration from the exhaust pulses.


Bottom and top hinge pinned together while the flox dries....getting there. All cowl hinges are now installed. I needed to get this task done so I can move onto my plenum/baffle fitting since their fitting is most definitely inter-related.


Here I am starting to do some initial fitting and mounting of the baffles. I will need to trim these down quite a bit as I move forward....they really give you a lot of excess material to trim.


Placing my Sam James plenum on top of the engine to take a look at the fit. I need to make the Van's baffles work with the SJ plenum...no instructions on how to do this (the SJ instructions are not very good...but Sam says to call him if you have issues), so this will take a little brain power on my part as I get them to play well together.


A parting shot of my seats...still love the way these look! I better...right! I installed the hinges for the seat backs and want to drill through holes in the seat pan for the seat heater wires next. Then I will start putting together a plan for my center console construction. Once that is complete, they will be removed and set aside until much later as I finish up and get ready for the maiden voyage.

Friday, September 7, 2012

Primary Sequence HOBBS 1502.5 hrs


Last night was my 5th flight in the Pitts. During this lesson we were going to tackle the competition Primary Aerobatic sequence. This is where all budding aerobatic pilots start. The categories for competition evolve like this: Primary, Sportsman, Intermediate, Advanced, Unlimited. The primary sequence is really not that daunting when looking at it on paper. It is a 45 degree upline, a one turn spin, half cuban, loop, 180 degree turn and ending with a slow roll. The diagram shows the sequence in Aresti shorthand, we put this in the cockpit to reference. With the primary, its not too hard to memorize the sequence, but the upper level sequences are much more involved.

For a new aerobatic pilot trying it for the first time, it gets pretty taxing in a hurry as you try to string maneuvers together, manage your energy, fly straight lines...and oh, by the way, stay in this tiny aerobatic box! From the air, the aerobatic box looks like the size of a football field....are you kidding me?! Its actually quite a bit bigger than that, 3300' x 3300' to be exact...but I was amazed just how small that puppy looks from the air.

My brain was on mental overload as I attempted this, so much to think about...and fly the airplane at the same time. There is a saying that pilots that do recreational aerobatics are called "floppers"...you can guess why and probably where that term came from. Their purpose is just to go out, have some fun, and "flop" around the sky willy nilly, paying no attention to style points or precision. Nothing wrong with that at all, but if you really want to hone your stick and rudder skills, try competition aerobatics. It takes it to a whole new level...and I gotta say, I like it...it is a true aviating challenge to demonstrate that kind of mastery over your aircraft.


For about two weeks I had been memorizing the sequence and going over it in my head. Planning my energy management strategy and closing my eyes, flying it in my mind, and going through the stick and rudder motions. When I showed up at the airport, I told Dagmar, "I wanted to test myself...first time through, unless it is a safety concern, don't say anything...no coaching...let me try to get through it alone. Then when I finish, we can discuss what I did right and wrong." She said "ok, sounds good."

Mind you, I wasn't completely prepared for this and I knew it...I hadn't done a 45 degree upline yet, my cuban eights in my first lesson were not to competition standards and my slow rolls were still a work in progress. But, I believe in pushing yourself...that's how you grow and learn at anything in life, get out of your comfort zone and stretch. I knew this was going to quite a learning experience...I was not wrong.


Ok, so...here we go...we get out to the practice area. I line up at 3500' AGL and make a shallow dive into the box. Stiff pull through 1/8 of a loop, establish my 45 degree upline...good...up we go, airspeed decays to 80mph, push the stick and nose over the top, trying to mirror the initial pull...they should be equal in appearance, but the trick is the push at the top is at a much slower speed so its more gradual. I come out of the 45 degree upline and we experience a slight weightless zero G feeling as I float out of my seat and am constrained gently by my lap belt. Level off...always level off in between maneuvers, remember straight lines...the judges are watching.

Now cut the power, hold the nose up to maintain altitude...straight lines...setting up for the one turn spin. No problem so far, I'm feeling good. We wobble and teeter at stall speed, that's my cue to kick left rudder and over we go into the spin. Here is where it starts falling apart for me. I had never done a "competition" spin yet...although I knew about coming out on heading, a one turn spin requires a perfect 360 degrees of rotation...not 350 or 370. I also knew that coming out of the spin, I had to establish a perfect vertical downline, but I hadn't practiced that yet. I managed both of those fairly well for my first attempt, but what caught me was this.

I pulled power to enter the spin...got my vertical downline established (actually not quite, needed more forward stick...), but then forgot to add the power back in! When we practiced spins before, we didn't cover this, my only thought was recovering from the spin back then...not making it look pretty. As I came out of the dive, I pulled 4G's to level off...then, and only then, I finally added the power back in. Too late, my energy management was now destroyed...I didn't have the energy for the next maneuver (or at least I didn't think I did)...the half cuban. Consequently, this is where I aborted my sequence. Boy, I didn't get far, did I? doh! Quite an aviator alright! Oh well, it was a great learning experience and a wonderful introduction to the challenges of competition aerobatics. Energy management is everything.

We then circled back up to gain altitude and talked about it. Dagmar explained, I needed to establish a perfect vertical downline first, then add full power...while still pointing straight down. That was interesting the first time, instincts tell you "full power, straight down" is not a good idea for preserving life.

I went through it again...this time, making it all the way through the sequence. Its wasn't pretty but I managed. We ended up doing it several more times...and I was proud to say, I improved each time. The last one being pretty decent, at least from my vantage point...not sure judges would agree. Although, I did not stay inside the box on any of them...that will be the next challenge.

This was also the first lesson Dagmar let me take off and land. Take off wasn't too difficult, although Dagmar likes to take off in a three point attitude in the Pitts, which was different for me. I always raised the tail first in the Citabria. Landing was definitely another completely new experience. We came in at 1000' AGL, 120mph...when I was at about a 45 degree line from the numbers, cut the power to idle, pitch the nose over and glide down to the numbers...holding 110mph. Its amazing how the Pitts will glide at that nose down attitude without gaining airspeed. I round off, flare and set it down nice and smooth...Dagmar comes over the intercomm and congratulates me, "nice job!". I was feeling kinda cocky, until the beast showed me her fangs...here comes the ground roll. Holy moly is this airplane twitchy!! I was all over the runway, chasing my tail. Dagmar had to help me with the rudder on that segment of the landing...ok, I am now humbled again, that didn't take long. The Pitts is legendary for being hard to land...I can now see why.

I now have 4.9 hrs in the Pitts, with 2.0 hrs devoted exclusively to spin training. I would say, this, for me is a minimum for feeling comfortable flying solo aerobatics. I feel I have enough training now to know how to get myself out of trouble. I, by no means, have this mastered...but I have a good foundation, to practice my skills. I will continue with Dagmar to increase my confidence level...and I like flying with Dagmar and love the Pitts, but I would think most pilots would be ok on their own at this point. Those 5 hrs have meant the world to me being more confident in the cockpit. Spin training was HUGE for this pilot to erase my fears. Remember, I was a pilot that was afraid of doing solo stalls before I started this, I now would feel comfortable not only doing solo stalls...but solo spins, which I plan to do soon in the Citabria. What a difference! I cant recommend this training enough...it is an investment that will pay huge dividends.

During aerobatic lessons I empty all my pockets and there are no loose items in the cockpit for obvious reasons. Its a shame, I would have loved to have a camera with me on this flight. We landed just as the sun was setting over the Rockies and that flight back was nothing short of spectacular as we flew into the setting sun and it glinted off the red Pitts wings! Such a great time of day to be flying...in a Pitts.

Lastly, Dagmar is heading for Texas next week to start practicing under the watchful eye of her coach, Sergei, for the US National aerobatic championships at the end of September. She is hoping to secure a spot on the US National team. She was previously a member of the German national team in '94 and '96. After an aviation accident that claimed the life of one of her close friends, she actually gave up flying for a while. Only to come back to it recently, because as she says, she was "born for this" and really missed it. After getting back into flying...she set a lofty goal of once again trying to make the National team. I commend her on this effort, she recently told me she is just one year younger than when her mother died of cancer...we never know how long we have, go out and live...chase your dreams while you still have the chance.

Tuesday, September 4, 2012

Seat Belt Pads HOBBS 1502.5 hrs


My custom seat belt pads arrived Friday, and like the seats, look fabulous! These are actually Crow harnesses with Hooker pads with matching leather...it took some doing to get this accomplished, but I saved probably ~$500 in the process. Hookers (harnesses, that is...) are just way overpriced! ;) I love my Crow's but I wanted to have matching leather. Although I talked Luke at CAD into doing this, as he had never done it before, he said he probably won't offer it again. But...my advice if you want to go this route, is just procure the material from CAD and then have your local upholstery shop do it for you...they are dirt simple to make. I still need to add some snaps to hold the pads in place...but I've already found a DIY kit at the local boat shop, should be a piece of cake.

In other news...I have surpassed 1500 hrs on the project HOBBS! Wow, its crazy to reflect back on the journey to this point...a whole lot of activity went into that 1500 hrs. I've come a long way...

And, in still other news...I am ecstatic to report that as of this morning I have chosen my hangar location. I was presented with an offer I just couldn't pass up. Last weekend at the airshow, Bob Markert said he was looking for two hangar mates and I told him I was very interested...just needed to ponder it for a few nights. Well, there wasn't much to think about really...part of the fun of building an RV is the social aspect of it. Hangaring with Bob at BJC will fill the social aspect perfectly...not only do I very much enjoy Bob's company, but Sean Thomas, Jim Gray and Steve are in the same hangar row...just a few down from us. It should be a great group to hang out with...I'm very much looking forward to it.