Vertical stabiliser and other bits

I managed to complete construction of the paint shop over the previous weekend and set about painting the vertical stabiliser parts. This was done with standard green aircraft zinc-chromate rattle cans.  it quickly became apparent that this was neither efficient or easy, as the nozzles are useless and you don't get much paint in a can!

So the next stop was down to a local automotive paint suppliers for advice - what can I safely spray at home?   The answer was 1K acid-etch primer which comes ready mixed and you don't need forced-air breathing kit - a special disposable mask is OK along with goggles.  So suitably equipped, and using the compressor bought from Ebay and a small touch-up gun from Tool Station, I proceeded to prime all of the rudder and anti-servo-tab parts including the skins..  However, as you can see, they're grey!  What matters most is that the primer sticks well and doesn't easily scratch off.  

Rudder parts

Anti-servo-tab parts.

The next step was to finally start assembling some of the painted parts and hopefully see something that resembles an aircraft structure.  I started with the vertical stabiliser hinges and then the main skeleton in accordance with Van's directions.

First solid rivets in the rudder hinges.

Completed vertical stabiliser skeleton

Next job was to trial-fit the vertical stabiliser skin, and voila - something that resembles a finished part! You have to admire the quality of the kit in that all of the pre-punched holes in every part line up just perfectly.

Once the skeleton has been inspected by Jerry (with the skin off again), I can rivet the skin on permanently.  You can also see in the picture that the upper hinge is now fitted and the lower is tied on ready for the next stage.

Assembled vertical stabiliser.

Another job this week prior to fitting the VS skin was to rivet all of the anchor nuts that secure the forward fairing - fiddly work particularly close to the leading edge, and awkward to do on your own, so a good use for cleco g-clamps.

Final job this week was to start assembly of the rudder skeleton.  I only manage to complete the top hinge and rib installation but the rest is cleco'd together,so not much more to do before it can be skinned.

Partly-assembled rudder skeleton.

Upper hinge on the rudder spar - not all rivets face the same direction!

I have a busy time with paying work this week (I have the fund the RV somehow!) and have a weeks holiday coming, so little will now happen for a fortnight.  After that I should make rapid progress to complete the tail section.

Slow progress!

Well I didn't get as far as planned this week.  I managed to complete preparation of the vertical stabiliser skins - dimpling the rivet and screw holes and the matching anchor nuts. The did mean grinding down my 3/32 female dimple tool for the rivets that fit next to the dimpled screw holes.
I also worked out how to cut lines in the blue plastic covering without scratching the aluminium - polish the end of a fine-point soldering iron and then draw this across the surface to burn a thin track into the plastic sheet.   It can then be pulled away to leave a clean area for riveting.  I guess I should prime this area of the outer skin before riveting so there's paint below the rivets.

                                              Vertical stabiliser skins all dimpled.

I managed to prepare all of the rudder parts ready for painting, although I'm meant to check that the hinges line up correctly with the completed vertical stabiliser before I can rivet them, so I'm now a bit stuck.

                                                         Rudder spar with control horn

Rudder spar top hinge.

As I can't get any further until the bits I've done so far are painted, I decided to sort out a paint area which can remain available all of the time and not rely on putting a car outside and masking off the workshop.  I've therefore started converting the loft of my garage into a closed-off dust containment area (using loads of plastic sheeting) and I'm fitting a high-volume extraction system (posh kitchen/bathroom extractor).  I'm also adding some better lighting.
This will give me a space 11 feet x 7 feet which should be big enough for the largest components. All being well, this will be finished mid-week and I can get the initial parts painted and assembled.

I'm only painting the internal structure myself - parts that will be hidden on assembly but need protection for corrosion prevention.  I'll have the aircraft external paintwork done professionally after completion of flight testing.

Underway!

I finally finished unpacking the crates and completed the inventory by Wednesday evening. Everything now has a home and hopefully I can find bits when needed!   We can now get both cars back into the garage until I need floor space for the wings - probably early in the new year.  At that time, Deb's car will have to go outside - the MGA clearly can't!

 Well done IKEA for a great range of good quality plastic boxes which are really cheap.  

I've started work on the first section - the vertical stabiliser (which is allegedly the easiest bit to build), and the parts are now all prepared (trimmed, match-drilled, deburred, fluted etc) and ready to paint prior to final assembly.  I did have one panic - I thought I'd countersunk some holes on the wrong side of the spar and it took me while to understand the use of the holes and why they are countersunk as they are. Fortunately I'd got it right or it would be more expensive freight and delays in getting new parts!    Pays to read the drawings loads of times before you commit to anything.

One unexpected bit of good luck popped up today.  A gadget I acquired as part of a job lot of tools purchased from Gumtree (pillar drill, lathe, band saw, scroll saw and some odds and sods) turned out to be a very slow speed electric screwdriver with a remote power pack (you can see it at the back of the bench in the picture below).  It accepts the hexagonal deburring tool I bought from Cleveland Tools in the 'States and makes dealing with cleaning up all of the drilled holes really quick and easy.

Above are the two hinge assemblies for the rudder.  

Next week I'll be working on the vertical stab. skins and starting on the horizontal stabiliser, rudder and anti-servo tab frames.  Once I have all of the empennage control surface parts prepared, I'll paint everything at one go and then blitz the assembly.

The kit has arrived!
Well after 6 weeks in transit by sea, the 5 crates finally arrived on Monday.  With help from John, David, Scott and Terry from Fairoaks and son Sam, we managed to get it all unloaded without incident and now it's safety in the garage and I'm working my way through unpacking and checking the inventory and trying to record where parts are stored so I can find hem when they're needed.   Some bits actually look like they're aircraft parts so there's hope yet that the end result will really be an aeroplane!

Almost ready!

Having made the decision to build an RV12 and placed an order back in April, the big day is almost here.  The kit arrived at Southampton docks on Monday night and will be delivered to me on August 10th.  I can't wait to get started!