Jerry Greenberg's Build Log of Van's RV-12 LSA

Stick Boots and Rudder Lock

2012-01-18T15:20:00.003-05:00

Today I installed my stick boots that I purchased from Flightline Interiors (click here) as well as a homemade rudder lock that I copied from a fellow builder.

The stick boots took less than 10 minutes to install ... my kind of installation. I think they look great and they will prevent a foreign object from entering the opening where the stick exits the inside workings of the aircraft. The quality is excellent and they have a zipper on the bottom. I didn't have a scissors at the airport to cut off the ends of the ties ... add another 5 seconds to the installation time.

After

Before

The rudder lock should come in handy on windy days when I park my RV-12 as well as when the line men move my plane out of the hanger to get at someone else's craft and leave my RV out for a couple hours or so when I'm not even at the airport. The lock consists of 1/2" PVC piping, 3 tee fittings, 2 elbows and an end cap.

Video over central Florida from SRQ to OBE with smoke from brush fires in the distance ...

THE MAN ...

2012-01-09T21:27:00.001-05:00

Top picture is of Richard VanGrunsven, the RV initials of my RV-12, who is founder and CEO of Van's Aircraft and me. The picture was taken at Sun 'n Fun in Lakeland, FL last year. Van is always happy to pose with us RV'ers and/or sign merchandise purchased at his exhibit. He's a really nice guy ... a true gentleman.

Today's flight was from Sarasota-Bradenton (KSRQ) to Naples Municipal (KAPF) a 171nm roundtrip. I only heard the Dynon 180 buzzer once ... and that was at the end of the flight in Sarasota as I was slowly taxiing back to my community hanger. It was for the left exhaust gas temperature (EGT) which indicated a low temperature for a second or two and then corrected itself and fell silent.

My previous problem with the left cylinder head temperature (CHT) may have been corrected at Lockwood Aviation the previous week. The buzzer was silenced for the CHT and since then the indicator has shown it behaving more correctly and consistantly in the green. My next oil change will be at 50-55 hours on my Hobbs ... currently at 41.1 hours ... and then Lockwwod will remove my cowling and find out if I have a bad connector or loose wire ... whatever ...

I've included a couple pictures of today's flight ...

Departing KAPF for KSRQ ...

Flying north, west of KSRQ, followed by a long right base then final for runway 14 ...

Video shows downtown Sarasota, FL ... St. Armand's Circle and Lido Beach ... Longboat Key in the distance ... then back to downtown Sarasota ...

Video shows Siesta Beach on Siesta Key, FL ... named #1 Beach in United States of America for 2011.

Unfortunately, a good pilot had a bad landing in his RV-12 which percipitated Special Safety Bulletin # 11-12 -14 for finishing kits shipped prior to 11/5/2011 ... that includes me. Seems that during an extemely hard landing if the main landing gear in forced aft the gas tank will be damaged and spill its contents  ... gas. It entails the gas tank be removed ... face plate removed ... two clips and frangible bolts added ... then reassemble the gas tank and reinstall. Oh well ...

                              Damage to an RV-12 gas tank after a very, very hard landing ...

Click here to see Special Bulletin #11-12-14 ...

I'm using the ForeFlight App on my Ipad2 as a backup for my GPS. I use an external GPS, a GNS 5870 MFI to spot the airplane on my Ipad app. This is what it looks like ... the little blue aircraft is my exact location ...

The Dynon 180 has spoken ...

2011-12-07T19:30:00.002-05:00

Yesterday, I took my RV-12 to Lockwood Aviation at Sebring Airport to check out some warning buzzers that were sounding. At first, the alarms were sounding for low exhust gas temperatures (EGT) and low cylinder head temperatures (CHT). They were intermittent buzzers and then I was getting a constant barrage of buzzers ... mostly for high voltage and low and negative ampere readings ... so I prudently decided to have it checked out.

If I recall correctly, they found 2 connectors (somewhere under the cowling) that were either loose or disconnected. They installed a second ground wire from the engine to the firewall and two more grounds from the "junction box" to the two panels housing my avionics.

I plan on taking my wife Susan back to Sebring to take some "pinch-hitter" lessons so she can handle the RV-12 in case of an emergency. If I become unable to pilot the plane, I'd like her to be able to fly the plane, use the radio and declare an emergency, use the GPS to find the nearest airport and then "land" the plane. It doesn't have to be a pretty landing ... just good enough to walk away from.

Wife's First Ride in RV-12

2011-12-01T21:37:00.008-05:00

Today my wife took her first ride in our (my) RV-12. I do believe she really enjoyed her air time in the RV. I convinced her to hop aboard at 32 hours on the Hobbs meter and forgo her mandatory 40 hour requirement she has spoken of for over 3 years (even though the FAA said all I needed was 5 hours on the ELSA to legally carry a passenger).

On final at KSEF with a herd of steer just off runway 32.

RV-12 tucked in the back of community hanger before Sue's first flight.

My pleased wife and first time passenger.

Landing at Sarasota- Bradenton International Airport (KSRQ).

I love my wife but as you can see, as good as a passenger she is, that's how bad a videographer she is. I promise, I will soon buy a GoPro2 HD video camera (with a wide angle lens and 1) mount it on a headband 2) mount it on the wing tip then 3) mount it on the landing gear ... bear with me ...

Back 'n Forth from KSRQ to KSEF ...

2011-11-10T23:57:00.018-05:00

My lovely wife and I
(picture coutesy of Ross Cibella)

Here are a few fisheye photos taken of my RV-12 by my friend, Barry Shapiro. I really like these weird photos and hope you enjoy them.

I've also included a picture of my friend, Linda, who has followed the entire build in my garage whenever she came over my home to visit with my wife. I got the feeling she was really impressed with the finished plane. She and the photographer, Barry, have decided before I set my first rivet, that they will only enjoy my RV-12 from "the good ole terre firma.". If they only knew what they were missing!

I wish I could say I've taken many long cross-country trips so far but the truth is, I fly from Sarasota-Bradenton International Airport to Sebring Airport in central Florida, have lunch, visit with friends at Lockwood Aviation and return back to Sarasota Airport. Still it's fun and exciting everytime I make the trip! I've been to a few other small central Florida airports such as Tampa Executive, Bartow and South Lakeland, Okeechobee, North Palm Beach and Charlotte County Airport ... and believe me, soon, many more to follow.

The above picture shows the Sebring International Raceway as well as a piece or KSEF's runway 36.

The pictures above & below are from my KSRQ-KSEF trip today. I don't think the fun and excitement of flying will ever get old! Still, so much to learn ...

So far I have 32 hours on my Hobbs and when I have 40 hours on my RV-12 my wife says she'll hop in for her first ride with me in my "homebuild" Experimental Light Sport Airplane (ELSA). Our first long cross country will be to Charlotte, NC.
My Garmin 496 has a cross-country flight from KSRQ to KAYS (Rock-Hill; Bryant County Airport in South Carolina) where we will be picked up by my daughter and son-in-law and visit with them and my granddaughter. They live in North Carolina but can walk to South Carolina from their home.
After a few days with them it'll be on to Greenboro, North Carolina to visit my other daughter's family and spend time with my grandson.

Now those are two trips I'm really looking forward to make!

Time for Rotax Maintenance

2011-10-04T21:15:00.015-04:00

I took my RV-12 in for the Rotax Engine oil change and engine check-up required at 25 hours on the Hobbs meter. My timing was pretty good ... I had 25.7 hours on the meter.

Video below and photos above of Lockwood Aviation technicians performing the 25 hour Rotax service on my RV-12.

By the way, this year's Lockwood Aviation Supply Catalog has a picture of an RV-12 on the cover!

The technicians at Lockwood Aviation in Sebring, FL advised I get the oil changed at 25, 50 then 100 hours ... and every 50 hours thereafter. But when they learned I was using 100LL fuel they suggested I get the oil changed every 25 hours ... since I was exclusively using fuel with lead. Then it was decided if I add 10 gallons of auto fuel occasionally (Shell, Exxon, etc. 91-95 octane with 10% ethenol is O.K.) I could go about 33 hours between oil changes.

So I therefore decided to buy 3 five gallon gasoline containers and fill them will three and one third gallons each (so they won't be that heavy) and add that gasoline to each ten gallons of 100LL gas left in my gas tank; combining the two types of gasoline to go 33 hours between oil changes. I bought a quart of TCP additive ($35.00 per qt.) which I will add one once per 10 gallons of 100LL fuel to keep my Rotax running clean!

Pictured below is my new community hangar owned by Dolphin Aviation at KSRQ. The doorless white hangar with a rectangular opening, about 100 yards in the distance was my previous community hangar location.

I was advised by the FAA examiner, who gave me my air worthy certificate, to take and pass the ELSA Repairman's Course. Passing that course would allow me to do my own annuals on my RV-12. But even when I pass the course, he said "but always pay an A&P to perform that procedure ... don't do it yourself. Builder's have a way of not performing all the items on the check list ... a good A&P will." So I plan of taking the course, passing it and paying Lockwood Aviation to do my annuals. Just my personal decision ... other builders will do as they like ... it is a free country.

Twelve seconds over KSRQ left downwind for runway 04 on a very "bumpy" day.

I would also like to thank all you RVators and airplane enthusiasts on Facebook who took the time to vote for my grandson at the Huddle House Restaurant web site as described in my previous post . The contest ended on October 2nd. and he won an Ipad2! He was so excited. Thanks again for your votes ... they were greatly appreciated.

Totally Unrelated!

2011-09-01T22:09:00.024-04:00

A relaxing September 11, 2011 ... unlike 10 years ago today ...

All you RV builders, aviators and airplane enthusiasts following this blog who are also on Facebook ... I've a favor to ask. Please click on this HUDDLE HOUSE LINK (CLICK HERE) and vote for my 4 year old grandson, Bridger. He's a great kid and would be so excited to win an ipad ... At four, he knows how to play on his friend's ipad ... and they play games and learn from educational apps. If he were to win his very own, he would be so excited. You can vote for him once a day, everyday, thru Oct 2nd.

Here's the picture to look for ... he's holding up a piece of crispy bacon ... what a great smile!

... now back to N124JG ...

My -12 is currently in a "Community Hangar" with about 11 other aircraft ... and the workers there are constantly moving the planes around to get a plane out of the hangar for someones next flight. When I come in to see my plane in the morning, I have no idea where my RV-12 might be ... in the back or front or middle of the hangar. and I tend to worry a lot. I've heard stories about "hangar rash" from many a pilot ... old timers and new pilots. You may soon see my plane back at the old portable hangars at KSRQ where it was during construction.

The weather in Sarasota, FL has been pretty bad since I flew my plane back from Tampa Executive Airport where it was painted. I still have 18 hours on the Hobbs and at 25 hours I'll be taking it to Plant City Airport to have the oil changed. Sensennich Propellers are manufactured at this airport and my mechanic said he will have them check the propeller balancing just to be certain it's A-OK. He feels it may be ever so slightly off balance. We'll see.

Now that my plane is complete, I've decided to continue this Blog ... and share all my future RV-12 adventures. My plans include ... after my oil change ... trips to Key West, Savannah, St. Augustine and NC to visit my granddaughter and grandson. Then I hope to fly to each state in the lower forty-eight. I just have to wait for some good weather and a bit more experience. I can dream, can't I?

Finished at Last ... Let the Adventures Begin!

2011-08-25T08:42:00.001-04:00

A "walk-around" video of my completed RV-12 at SRQ's Dolphin Aviation ... note the "N" numbers are affixed and Hawk Aviation decided to add a couple red stripes on the outside of the rear canopy and forward back window to cover the roll bar and canopy frame to match the experior red color. Nice touch, I think ...

...and some additional inflight pictures ...

... approaching SRQ from a distance ...

... final home at Dolphin Aviation ...

... and a self portrait @ 3000 feet ...

Interior Upholstry Installed

2011-08-20T13:27:00.004-04:00

The combination of Flightline Interiors (click here) and Hawk Aircraft Painting (click here) has done wonders for the pieces of aluminum and steel, nuts, washers, nutplates, wires, bolts, plastic, avionics and engine delivered to my garage over the past three years.

I've included some interior pictures of before (taken thru the canopy) and after Flighline's interior option was added. In my opinion the difference is remarkable, well worth the cost. You be the judge.

Note the headset straps on the side panels ... I saw those pictured on Van's Air Force (click here ...then page down) as well as the fire extinguisher mounting location and decided both would be good ideas.

I currently have 18 hours on my Hobbs and at 25 hours I'll fly to Plant City, FL for my oil change and engine inspecton. After that, my adventures begin ...

more pictures of the paint job ...

2011-08-12T22:59:00.001-04:00

I think my RV-12 is lookin' pretty good about now. Next week my interior kit should arrive. I'm hoping to have the plane back in Sarasota Friday or Saturday of next week. Here are a few more pictures of N124JG taken at Hawk Aircraft Painting today.

the paint scheme continues ...

2011-08-11T10:29:00.002-04:00

Five more pictures received from Joe Dinolfo at Hawk Aircraft Painting (CLICK HERE) ... the paint scheme takes shape. Remember, my wife Susan picked the shades of red and blue ... and I like 'em a lot. I still haven't seen the plane in person since the painting began ... so far I think it looks pretty good & I'm hoping for the best ...

I spoke to Flightline Interiors (CLICK HERE) and they said my interior kit would be sent either Friday or Monday ... two days for delivery and a couple hours to install and my plane should be complete and flying by the end of next week.

... here comes da blue ...

2011-08-10T08:32:00.001-04:00

Here's the blue ... then the black ... Hawk Aircraft Painting (Click Here)

the Painting Process continues ...

2011-08-09T09:50:00.004-04:00

Additional pictures from Hawk Aircraft Painting (CLICK HERE), at the Tampa Executive Airport, have arrived this morning.

The first 3 pictures show the RV-12 with 12 inch "N" numbers (N124JG ... 12 for Jerry Greenberg) on the side of the fuselage. The 12 inch "N" numbers are required for international travel (Bahamas). Since I may go to the Bahamas only once or twice, I decided to go with 3 inch "N" numbers instead and favor the paint scheme over international travel (I may be able to put temporary decals on the side of the plane, a foot high, when I travel to the Bahamas). No matter, I'll go with the 3 inch numbers. If you look closely at the top picture, you can see the outline of the 12 inch "N" numbers. We didn't think it looked good with the huge numbers.

The bottom 2 pictures show how the paint scheme expands with space left for much smaller 3 inch "N" numbers. Notice how the design is extended further to the rear of the fuselage with room left for much smaller "N" numbers. I like it better this way. Joe Dinolfo, president and owner of Hawk Aircraft Painting, may start the painting process this afternoon. As the pictures arrive via E-mail, I will post them here. (See below ... past next two pictures for start of paint scheme).

The two pictures below show the first hits of the blue portion of the color scheme.

All Primed and All White ... So Far

2011-08-08T08:16:00.017-04:00

Joe Dinolfo, President and Owner of Hawk Aircraft Painting (CLICK HERE), has sent me four new pictures of N124JG during the painting process. As can be seen from the three photographs, my RV-12 is currently all white. Now they will reassemble the plane, tape it and cover the majority of it with paper as the red, blue and black designs are added. I may be slightly prejudiced, but personally, I think it's lookin' good already!

Once the painting is completed and the interior kit is added ... I think I'll have one beautiful airplane. I already know she flies beautifully.

And to think, it all started with the Wing Kit being delivered to my garage on May, 8, 2008.

(CLICK HERE)

The Painting Process

2011-08-04T16:59:00.006-04:00

Joe Dinalfo at Hawk Aircraft Painting was kind enough to send me 3 pictures of my RV-12 during the priming process. The day after tomorrow he will start painting the plane white ... then slowly and meticulously add the red, blue and black highlights.

While the paint is being applied, Flightline Interiors is finishing up my interior carpet and upholstery. To see what the interior might look like CLICK HERE and slowly scroll down the entire page. My interior colors will be similar, just a different shade of gray.

And finally it should look like this. Thanks again, Rudi.

Decision Reached on Paint Scheme & Shop

2011-07-23T15:51:00.012-04:00

The paint scheme I chose for my RV-12 is the one I've pictured in my last post ... what the heck, I'll post it again here. It'll be red, white, blue and black. My wife, Susan, will choose the shades of red and blue ... I'm confident enough to choose the shades of the black and white ... just black and white, no shades to mess up.

My RV-12 as it looks today.

My choice of paint shops was Hawk Aircraft Painting (Click Here) at Tampa Executive Airport. The paint job will take about 3 weeks. I've also ordered the interior kit from Vans Aircraft ... the plane will be fully carpeted dark gray, side "leather" panels in light gray, red armrests the fuel tank behind the passenger seat will be covered with carpeting. The rear bulkhead will be in light gray "leather" and dark gray carpet with EXPERIMENTAL embroidered in red. I'm hoping it'll look good.

Dissembled RV-12 at Hawk Aircraft Painting.

All my RV-12 videos, both building and flying videos can be viewed by CLICKING HERE.

The following video was taken from my RV-12 while flying from Sarasota-Bradenton Airport (KSRQ) to Tampa Executive Airport (KVDF). (You might have to refresh this page on your browser for the video to show up)

Airborne Photos & New Hangar @ SRQ

2011-07-11T07:00:00.017-04:00

These top two pictures are the planned paint scheme for my RV-12. This scheme was used by Rudi Greyling in South Africa on this RV-12. I liked it so much that I may use it also ... "imitation is the sincerest form of flattery" ... thanks Rudi. Remember, today my plane is the one that's half primed and half unfinished aluminum. But one day ...

A friend was kind enough to take pictures of N124JG airborne between Sebring and South Lakeland Airport.

Also including a video of my -12 arriving at it's new community hangar at Dolphin Aviation (KSRQ).

Somewhere between KSEF and KSRQ as seen from my new RV-12

N124JG Takes Flight!

2011-06-03T20:31:00.014-04:00

After 37 months of "stop 'n go building", N124JG finally put air under it's tires! It was a little "crow hop" during a fast taxi on runway 32 at South Lakeland Airport. If Howard Hughes can claim the Spruce Goose flew with his 70 ft. flight off Long Beach, CA in 1947, then surely I can claim my RV-12 has flown too. To see my RV-12 leave the ground for the first time, CLICK HERE. Howard's plane flew only once, whereas I am planning many longer and higher flights in the coming days.

Day Two Flight Test (a little longer, faster & higher) CLICK HERE

Day Three After Flight Test Taxi Back to Hanger ( Jay Kurtz test pilot) CLICK HERE

All My Airplane Videos from 2007 to Present Day CLICK HERE

Today began with an FAA inspector examining my RV-12, going over some important paper work and then issuing the coveted Airworthy Certificate for my ELSA (Experimental Light Sport Aircraft).

The green paint you see on the forward half of the plane is merely a primer. I may prime the entire plane and then get it professionally painted.

It appears that serial #120003 is the 107th. RV-12 to take flight. Seems 104 builders jumped ahead of me to finish their -12s. Mine's not the fastest build to take place ... in fact, as of today, it is the slowest RV-12 build on record. Maybe I'll get an award! But given time, I'm sure my record will be broken.

Best wishes to all those who are currently building ... remember, 37 months is the record to beat ... or not.

Milestone: First Engine Start!

2011-04-28T06:07:00.011-04:00

My Rotax 912 ULS engine was started today for the first time. All went well ... no leaks, no runs, no errors as we builders like to say. This engine start occurred after 36 months on stop 'n go building.

The gentleman in the picture wearing the baseball cap and leaning against the engine is Jim Lemley. He has been working on the RV-12 for many hours since it arrived at South Lakeland Airport last October. We are both eagerly anticipating our first ride in the plane. Since we are currently awaiting the FAA inspector to arrive in the next 10 days to two weeks, the initial flight should occur in the month of May. We'll see ... (cautiously optimistic)

I've included three videos; a Walk- Around of the RV-12 as of today (CLICK HERE) as well as the First Start of my Rotax engine (CLICK HERE)... & Early Ground Taxi (CLICK HERE)

Stay tuned, next post should be the first flight on N124JG, serial #120003. There are currently 100 RV-12 flying around the world!

New Prediction ... hope to fly in April!

2011-03-16T13:43:00.005-04:00

As I wrote in my last post ... I hoped to have air under my tires in March ... if all goes according to plan. Well let me make a new prediction ... hopefully the maiden flight will be in April.

Brake fluid, oil and gasoline are all in my RV-12. Lots of little things to do like attach the wings (a 2 1/2 minute job) and of course the FAA inspector has to give me the final go ahead in the form of an Airworthy Certificate!

Hope to see a few of you at Sun 'n Fun in a couple of weeks. Since 95 RV-12's are flying, I'm sure a few -12's will be Lakeland for me to see. I need to come up with a paint scheme soon.

So let's say April ... yeah, yeah ... that's the ticket!

Getting Closer to the Finish Line!

2011-02-12T18:24:00.005-05:00

If all goes according to plan, N124JG should have air under the tires in March ... if all goes according to plan ...

There are 93 RV-12's that have flown and the last I heard 500 kits have been sold so far. My kit# is 3 ... serial number 120003 to be exact. There's a good chance Jay Kurtz will fly off the mandatory first 5 hours then fly with me one or two hours for a little check flight. Then a paint job at the Vandenberg Airport and a "leather" and carpet interior package to put the frosting on the cake ... so to speak.

I'm keeping my fingers crossed that all goes according to plan.

Spinner, Prop and Throttle

2011-01-26T20:38:00.003-05:00

A little more progress has been made with the spinner, prop and throttle completed. Slowly but surely it's beginning to look a lot like the 90 RV-12's that are already flying.

It's Been a While ... but I'M BAAACK!

2011-01-14T19:17:00.009-05:00

My kit was moved from Sarasota-Bradenton International Airport in late October to South Lakeland Airport (X49) where Jay Kurtz and I were to finish the canopy, Avionics kit and Engine kit together. Unfortunately, I was told by my cardiologist I needed to undergo my 2nd. triple by-pass surgery. So I gave Jay the go ahead to complete the RV-12 without my help. Jay has build many, many RV's, including several RV-9's and 9A's as LSAs. Anyone needing assistance completing and RV can go to his web site for information ... just CLICK HERE.

So far the canopy is 95% complete, the avionics kit is installed and the engine is hung but not completely finished.

It looks like my RV-12 will be flying by mid-March or sooner. I can't wait! The last time I checked there were 90 RV-12's completed and flying. I still might be in the first 100 to fly ... if not, I'll be in the 2nd. 100 to fly ... obviously it makes no difference to me. I just want to fly ... finally.

In the above pictures, Jay is the guy in the yellow shirt and that's me in the beige jacket.

When the plane is complete and flying, I'm still going to say I built it in my garage and take 100% of the credit for the build ... who's really going to know? ... unless they read this blog!

Been Away From the Build a While

2010-06-25T18:30:00.007-04:00

I know, I've been away from the build for about 3 months. And it'll be another month or so before I go back to a daily build cycle. I have a beautiful new granddaughter in Charlotte, NC and my other daughter bought a new home in Greenboro, NC. So once my RV-12 is flying, I'll be flying from Sarasota, FL to North Carolina quite often.

Both wings are finally attached with the flaperon torque tubes drilled and working. The cables to the stabilator and rudder are installed and working. Next comes the canopy, instruments and engine. Then my RV-12 will be complete.

The Avionics kit is at my home and the Engine kit is on order.

I'm still hoping to be flying by the end of 2010. As of today, there are 51 RV-12's flying. I hope to be in the first 100 to be airborn ... we'll see. Fortunately it's not a race. Even thought I started the build in May of 2008, I've only worked on the plane for about 14 months ... about 1000 hours so far.

Video of Build @ 959 hours

2010-03-22T21:22:00.010-04:00

I took the last 3 weeks off to play with my 3 year old grandson who was visiting with his Mom and Dad from Oregon. We had a great time traveling to NC to visit my other daughter and her husband, going to playgrounds, kid's museums, the beach, backyard pool, Target to buy toys, restaurants and so many more fun adventures.

Tomorrow I'll get back to working on the RV-12. The first thing I'll have to do is redo the cable-turnbuckle attachment points for the stabilator. One turnbuckle has 2 threads on one side and 8 threads on the other side. The plans call for three threads on each side showing but others have told me that is too tight a reading on the tensiometer ... I imagine Van's Aircraft will issue a revision eventually for that procedure ... I'm hoping I can achieve the correct tension with approx. 5 threads on each side ... considerably more balanced than what I currently achieved. I'll let you know how it works out for me in a day or two. The above pictures of cable attached to turnbuckle is incorrect and will be corrected. Remember to check with Van's Aircraft Builder's Assistance for the final, 100% correct advice.

I made a video of my RV-12, currently located at KSRQ (Sarasota-Bradenton International Airport) at 959 hours of construction. Click here to see that video.

There are currently 25 RV-12 flying. Congratulations to all those builders!!

Rudder/VStab & Stabilator Final Install

2010-03-11T19:41:00.006-05:00

The rudder, vertical stabilizer and stabilator have been installed for the final time ... I hope. The rudder cables are attached as well as the stabilator and cables and the stabilator trim. I hope that's the last time I have to install the empannage. Attaching these control surfaces was difficult due to the washers that had to be installed in the process. It took 2 assistants to get the installation done ... and yet I heard from another builder that he did the same all by himself. Unbelievable!

There are currently 24 RV12's that have been completed and flying. I hope to be added to that list ASAP. Maybe by September 2010.

Sat in Plane Making Engine Noises

2010-02-23T23:08:00.003-05:00

I began working on my RV-12 in my hanger at KSRQ. Makin' progress.

Started by working on the rudder cables. It's very difficult to get into the cockpit, lay your stomach (best to have a lot of pillows) and attach the rudder cables and cable links to the rudder pedals. The hard part is getting the cotter pin thru the bolt and castle nut.

Pat, pictured above, came up with the idea to remove the castle nut ... mark the hole location on the head of the bolt so the hole location in the bolt can be found and the castle nut aligned up accordingly ... much easier. We'll proceed that way tomorrow and then attach the stabilator and and cables ... I hope.

Pat took the pictures of my first venture sitting in the cockpit ... I look like I fill the whole cockpit but the is really plenty of room ... Fortunately for me, Pat is a much better builder than he is a photographer. Thanks again Pat for all your help.

Moved to Hanger @ KSRQ

2010-02-19T20:11:00.018-05:00

I am now officially continuing my build at Sarasota-Bradenton International Airport. I moved my hand tools, power tools, parts, 2 EAA work benches, sawhorses, chairs, tables, small refrigerator to SRQ on Wednesday and Thursday. Today, Friday was the big move ... with the help of my two friends, both named Jerry like myself, they (we) moved the RV-12 fuselage, wings and stabilator to the airport in just two separate trips.

When the two Jerrys arrived at my home, I was surprised they were towing an empty boat trailer ... not what I was expecting ...I had my doubts. But with some 2X4 scraps, some 2X2's once part of Van's crates, a portable drill, long wood screws, several tie down straps (not shown in the fuselage pictures ... sorry, but absolutely necessary), ropes, my wing rack and some muscle power, all went well. Jerry & Jerry ... thanks so much!

All I have left to move to the airport is my canopy which should slip into Pat's SUV (another friend who has helped me with the move and who has also built an RV).

If anyone reading this blog is thinking of building an airplane, any airplane, friends with experience or no experience, willing to help are as necessary and important as any tools, sawhorses or AN bolts ... make that more important than, because you can always buy tools but a helping hand is priceless. When we arrived at the airport, three other pilots (more new friends) helped unloading the trailer. Thanks again guys.

The people I've met since starting my RV-12 build have been a unexpected plus to the entire building process. I'm a lucky guy.

My wife's and my car have been in the driveway since May of 2008. Tomorrow they go back into the garage and then I'll continue to build my RV-12.

Gas Tank & Brakes

2010-02-10T22:49:00.006-05:00

The gas tank only leaks at the balloon connection ... that's OK since the balloon will be removed and an AN fitting will replace the balloon. There is also a tiny leak at the filler neck where there are two metal clamps and a rubber fitting ... a little more tightning of the clamp should take care of that ... therefore, the aluminum gas tank seems to be able to hold water ... or in this case gasoline. I painted the gas tank the same Satin Pewter Gray to match the interior of the cockpit. The gray paint hides a multitude of messy gas tank sealant on the exterior of the unit. Once I buy the optional interior kit, carpeting will cover all but the front of the gas tank ... and that will be covered by the passenger seat back and the seat back cushion (click here to see the optional interior kit ... page down to see entire interion kit)

The brake lines are attached continuously from the rudder pedals to the left and right disc brakes. Finally.

I'm still waiting for the temperature to reach into the 70's so I can begin the canopy. This is a chilly winter ... even in Florida.

If all goes well, I should have my project in a hanger at KSRQ (Sarasota- Bradenton International Airport) at the beginning of next month. At that point I'll be able to attach the wings and empennage and all the control cables.

It took almost 1 1/2 years of building before I discovered the AN bolt guage. No more measuring each bolt to determine which bolt I need. I just use the bolt guage. I wish I knew about that guage 18 months ago. Oh well ... better late than never.

By the way, since my RV-12 is on it's tricycle landing gear, I thought it would be a good idea to have some wheel chocks. So with all the tools I now have, I decided to build three wheel chocks and painted them safety yellow.

Canopy Frame in Play

2010-02-04T16:23:00.012-05:00

My canopy frame has been painted and mounted to the fuselage. I had a problem fitting a bolt into one of the nut plates but my friend, also named Jerry used a tap and all was fixed in a minute or so. It so helps to have knowlege and experience (his, not mine of course). Jerry also reattached one of my disc brakes for a better and proper fit. Thanks again, Jerry.

My fuel tank may not be leaking anymore. The balloon test is in progress as I type this post ... 8 hours and all is well ... so far. I'm still not out of the woods though ... more about that in subsequent posts.

I hope to start the canopy drilling and trimming soon ... believe it or not, but it's been a bit chilly in Florida and working on the canopy the temperature should at least 70 degrees or more. Florida weather will return in a day two. No problem.

I also included some canopy hints. Just click on the picture of text to enlarge (or any picture in the entire blog). Not my hints ... but from an Airplane Plastics manufacturer.

I ordered my Avionics Kit from Van's Aircraft. It will consist of:

Garmin 496 GPS (XM Radio-Weather)
Dynon FlightDek D180 electronic flight information system/engine monitor
Garmin GTX Transponder
Garmin SL-40 communication radio
Artex ME-406 ELT
Flightcom 403 stero intercom
plus all necessaryinstallation components & materials

It should arrive in about 3-4 weeks. I won't be ready for it then ... but soon.

After installing the Avionics Kit, I'll order the Engine Kit.

I think I see the light at the end of the tunnel ...

Balloon Test In Progress

2010-01-29T16:21:00.007-05:00

I began the gas tank balloon test today. I'll look at it tomorrow and see if I passed and finally have a leakless gas tank. I don't want to have to build a second one. Time will tell ( a day or two should do it).

Since I tightened up the stem core my tire problem is resolved.

I put a second coat of red on the roll bar assembly, finished painting the canopy frame and applied a clear coat on the upper arm rest and interior of the two turtleneck skins. No way I'm going to paint the entire exterior of the -12 ... will get it professionally done one day.

I attached the canopy frame and struts and had a problem fitting in the AN4 bolt in the aft point on the right strut. My friend Jerry stopped by with his friend Dave to see the progress I've made on my RV-12. While here, Jerry solved the AN4 bolt/nutplate problem with a 1/4 X28 tap. I never would have thought of that! Experience and knowledge is great ... his not mine. Thanks again Jerry.

Keeping my fingers crossed concerning the balloon test. Stay tuned!

UPDATE:

Later same evening ... my tank leaks!! Balloon was completely deflated! Will look for the leak tomorrow. To be continued ...

Baby Has A New Pair (3) of Shoes

2010-01-25T20:26:00.013-05:00

Yesterday I finished my redo on the fuel tank. I'm going to wait a week to allow the tank sealant to cure thoroughly and then test it with air from a bicycle pump and a balloon. All I can do at this point is hope for the best. I'll post the results in a week. For those who are unfamiliar with working with and mixing tank sealant, believe me when I say no matter how hard you try to be neat, you are going to make a mess. Maybe with practice and some sort of technique it can be done neatly. I plan on cleaning the exterior of the tank with the Dremel and a wire wheel and polishing wheel to trim up the messy exterior sealant after which I will paint the tank and apply a coat of clear seal. The tank will look pretty good when I'm done. Let's just see if it leaks first.

The stem core was not fully tightened on the tire that went flat. I tightened it up with a special tool I bought at Auto Zone and hope that will take care of that problem.

I used painter's tape and paper to once again paint the cockpit of the RV-12. All I did today was put a clear coat on the upper arm rests and the center bar structure beneath the roll ball. Tomorrow I'll spray clear coat in the inside of both turtleneck skins surrounding the rear window. Those are the main areas that will show even with the installation of the interior option kit ... Click here to see what that will look like... be sure to scroll all the way down the page to see it all. I'll also clear coat the non-roll bar portion of the frame and while I have to cockpit taped off I'll give the red roll bar structure another coat of Sunset Red Gloss paint.

My wonderful, beautiful, understanding, sweet wife and I were able to attach the two tires to the main landing gear this evening. I know it doesn't seem like a big deal but to me it was a milestone. Now when I finally decide to go to a hanger, I can roll the beast onto the trailer ... no more calling neighbors to move , flip, turn, lift the RV-12 onto workbenches, tables or sawhorses. All I have to do is roll it away.

Total build time to date is 915 hours. Still a long ways to go. Hope to be flying in 2010.

Both Tire & Gas Tank Leak

2010-01-21T20:25:00.006-05:00

I'm not a happy camper today. The gas tank I built will not hold gas and a brand new tire will not hold air.

I filled my gas tank with some water and placed it with the window side down ... very slow leak around the window. I filled all three tires with air and leaned them against a wall ... next morning one was flat.

I removed the rivets holding the top of the gas tank on, cleaned old sealant off and ordered more gas tank sealant (before and after pictures of gas tank sealent removed). When the sealant and "oops rivets" arrive I'll reseal the window and re-rivet the top on , let it cure and add water again ... if no go I'll build a new gas tank with all new parts.

Then I'll dissemble a main landing gear tire and search for a leak. If it can't be repaired I'll order a new tube. How did I get a flat even before the tire was on the landing gear? Oh well ...

The canopy frame has been drilled, riveted, deburred and primed and painted.

All in all, not a great day. Hope to have a few problems solved by my next post.

Back to the ... Gas Tank

2010-01-17T20:29:00.004-05:00

Well I finally finished the wiring section. I got hold of some "male socket pins" and it was finally completed.

I'll be ordering the the Avionics Kit before the end of the month. After that comes the Engine Kit ... and then I'm finished. Easier said than done. With a bit of luck I should be flying by the fall of 2010.

I installed the T1210 window and T1213I reflector ... not difficult but very very messy! I've yet to see if the gas tank will leak. I'll bet it will when I test it with a balloon and compressed air ... we'll see in a few days.

The fuel filler neck (T1211) and T1204B flange went smoothly as far as temporarily mounting the gas tank, marking and drilling the hole in the top of the gas tank and drilling out the gas tank lid hole. I'll be painting the fuel tank prior to final assembly so it'll look much better than the above pictures.

Still need to bolt the wheels on the landing gear ... soon. Once I finish the gas tank, my next major job will be the canopy. Because I'm building in a garage, I can't finish the contol cables to the rudder, stabilator or flaperon ... that'll have to wait till I get a hanger ... somewhere, sometime.

Once the canopy is done, I will be finished with the Finishing Kit. Amen.

Almost ... four kits down ... two to go.

On Landing Gear Minus Wheels

2010-01-14T21:43:00.003-05:00

N124JG is on its own three legs ... minus the wheels. Once again the installation of the left landing gear was a hassle ... but done with the help of two friends named Jerry also. Thank you so much fellas.

I'm still not quite done with the wiring. My 4 way indent crimping tool arrived from Stein Air. Unfortunately they sent me 12 female sockets (SA-1017) and 12 more female sockets (SA-1017) instead of 12 male sockets. So it looks like it will take another week or so before I get the correct parts I ordered. I do hope to finish the wiring some day.

Since I can't finish the wiring tomorrow, I may just install the wheels. We'll see.

Started on the Landing Gear!

2010-01-11T19:52:00.008-05:00

I was able to borrow that special sub D crimper tool from a builder at KSRQ. I repaired the "little gold pin" that came off the WH P-30 wire returned the harness and decided to finish up the next day. Well, the next day a different "little gold pin" fell off the assembly. I barely touched it and off it fell. Today I called Stein Air and ordered my very own Sub D crimper (SAT-004). If any more pins break off I'll be prepared!

In Section 32-11 you have to install six MS21919 adel cushioned clamps around two plastic sleeves surrounding the rudder cables. After several hours of unsuccessful attempts I started a new thread on VAF (Van's Air Force) asking if anyone had some tricks up their sleeves to get that job done (click here for that thread). Those guys came up with so many good ideas ... one better than the next. I decided to buy two different size hemostats in the housewares department at Harbor freight. It worked like a charm. Thanks guys at VAF.

Got a lot of help from my friend Jerry H. today. He (we) accomplished so much! All three tires were mounted on their wheels and the right landing gear was installed. That right gear leg (U1220R) was quite a hassle to attach. With the help of a 3' 2"X2" piece of wood and a hammer we were able to force the landing gear brackets into place. The bolts were a job to get into position also. But with Jerrys help we accomplished it! At his insistance, I'll wait for him to do the right landing gear ... no argument there! Thanks, Jerry.

There are now 17 RV-12s flying.

Happy New Year!

2009-12-31T15:51:00.004-05:00

Happy New Year!

To date I have a total of 843 1/2 hours into the RV-12 build. I completed the wing kit in 232 1/2 hours; fuselage kit in 314 1/2 hours; tailcone/empannage kit in 151 hours & so far have done 145 1/2 hours in the finishing kit.

Jerry was again kind enough to give me a hand building today. Once again, what he (and I) accomplish in one 5-7 hour day would take me several days on my own. There is something to be said for experience, knowledge & patience ... his, not mine.

The day before Jerry arrived, I made the Flaperon Pushrod Assemblies, Fork Assemblies & the Detent Bracket Assembly (Section 31-06,07) and Jerry was able to install them all. Trust me, the assemblies are more difficult to install than manufacture. Our F1266A Detent Bracket Assembly was a bear to install. The bracket had to be "reshaped" with a hammer, and a pair of crescent wrenches before it would slide thru the flap handle and fork assembly.

Pictures include my friend Jerry and a rundown of where I am as of New Years Eve December 31, 2009.

Once again, Happy New Year!

Flight Controls ... Good Progress!

2009-12-29T18:59:00.004-05:00

My friend, Jerry, spent the day with me and my RV-12 in the garage. He accomplished so much so quickly ... it made my head spin. Like a hot knife through butter, Section 32: Flight Controls pages 32-01, 02, 03, 04 and 05 were completed ... plus additional wiring connections were made.

On page 32-04 be sure you place the two F1262 Flap Handle Blocks around the Flap handle pushrod assembly and slip the combined parts into the tunnel together and then screw the assembly to the ribs. Thats the only way you'll get the assembly in.

I'm still trying to locate a specialized crimper for the the pin that broke off the WH P30 cable. When located, I hope to put Section 31:Fuselage Wiring Harness behind me, once and for all.

A Bit of Bad Luck ...

2009-12-26T16:13:00.002-05:00

On the last page of the wiring Section 31-14, I accidently broke off the tiny "gold" pin at the end of the white and blue wire of the WH P-30 cable and now I need to order some replacement pins along with a special circular crimper. I was so close to finish the wiring section ... and now I have to wait for the parts to arrive. Oh well ...

The first note in Section 32 says before proceeding with this section ... "reattach" and leave the empannage section attached. No can do in my 2 car garage so I'll do all I can minus the connecting the control cables to the empannage. I'll finish that up when I get to a hanger.

My halogen light had to be replaced so I went to Lowes and picked up two new halogen lights. These will come in handy when I get that hanger I mentioned a moment ago.

Almost Done With Wiring ... almost

2009-12-22T11:15:00.005-05:00

Finally, both fuselage pin assemblies work with the light test in Section 31-10 ...Ta Dahhhh! My friend Jerry was able to get the right pin working with the new parts from Van's Aircraft. We replaced the pin stopper, magnet insert and the magnetic switch on the right side. I was also able to install the F12125 over the rudder pedals wire tunnel without removing the rudder pedals ... took several hours of trial and error ... but it worked.

In Section 31-14, figure 2 it calls for two white wires from the WH-P30 but there was only one white wire. So I was told to connect all the colored wires called for in figure 2 then use the remaining colored wire as if it were a remaining white wire ... process of elimination, I guess ... works for me.

In Section 31-15 I installed the Artex ELT Bracket but before doing so I painted it with the interior gray paint I've been using.

Be careful in Section 37-04, figure 2, Bending the Float Arm. I matched it up to the wire in figure 2 and cut it before I realized there was a second bend and a 3/4" extention beyond the figure. Not a big problem ... had the piece welded on ... $10.00 ... oh well, just gotta be more careful.

I'll be starting Section 32:Flight Control very soon and I've decided not to reattach the empannage as it directs me to do at the start of this section because there is no room in my garage to do that. Instead I'm planning to attach the "mechanical" controls minus the cables, then move on to the canopy and landing gear without finishing and mounting the gas tank. Afterwards I'll order and install the Avionics Kit and Engine Kit in my garage THEN I'll move to a hanger at SRQ or VNC and finish the build.

There are currently 16 RV-12 completed and flying. And yes, I am jealous!

Gas Tank Sealant ... What a Mess!

2009-12-14T16:48:00.007-05:00

I just ordered the $10.00 F12125 improvement part in Section 31-13 to hold the wires above the rudder pedals instead of using the cushion Adel clamps which ususally give me a hard time to install. I've also manufactured a new WD1217C pin stopper with epoxied magnet inside in an attempt to get the pin light to test properly on the right side of the airplane (Section 31-06). I got the left side working and figure it's only a matter of time till the right side tests out properly.

I cleaned the tank sealant off the front of the gas tank. I applied sealant on the rivets holding the nutplates where it wasn't needed by mistake a few weeks ago. Today's photo page has the after picture of the front of the tank. ... As another builder stated, "the mistakes we make are not important ... but how we correct them is!"

No matter how hard I try to BE NEAT when using the gas tank sealant I still make a mess. I've got all the chemicals ready, latex gloves, tools, rags and popsicle sticks ready and still I make a mess. Fortunately the majority of the mess is INSIDE the gas tank and on me. Tomorrw will be more of the same. Very messy!

The Wiring Continues ...

2009-12-08T21:38:00.004-05:00

A gentleman who came to see my RV-12 build a couple of months ago was kind enought to call and come back to my home and assist me with my build today. He too is assembling an RV-12 and is awaiting the arrival of his final 3 kits. His assistance was much appreciated and he (we) were able to accomplish a great deal. We mounted all 4 headset jacks, grounded several wires, installed both control sticks, PPT-P and PPT-CP buttons as well as both hand grips.

The process of getting the PPT wires thru the control sticks (WD1212) was a bit tricky. Once we tried a string and used the air compressor to blow the lead string thru the control sticks all went a bit more smoothly.

The OAT (Outside Air Temperature probe) was mounted fairly easily a few day before.

From one Jerry to another ... thanks so much for the help.

December 1, 2009 ... and building once again!

2009-12-01T16:35:00.004-05:00

I was unable to build the entire month of November! My RV-12 sat in my garage and gathered dust. The first 20 days of the month my daughter and 2 1/2 year old grandson were visiting from OR and the remaining days of the month I was visiting my other daughter and son-in-law in Charlotte NC. But now I'm back building and still hope to have my plane airborne by mid 2010 ...

So far in 2009, for one reason or another, I was unable to build the majority of the months of April, July, August, September & November ... I wonder if I would have been finished by now if I had been building those months. My kit serial #120003 means I was the third person to receive an RV-12 kit and so far there are about 290 kits being assembled around the globe. I guess I won't be the first one done and I won't be the last one done ... I'll settle for somewhere in between.

There are now 13 RV-12s flying and all builder/pilots report the RV-12 as a fine aircraft to fly. I can't wait to join them!

I was able to get my left spar wing switch to work according to hoyle but am still having problems with the right one. Will get back to that at a later date as they will be accessible for the duration of the build. I'll just continue on the wiring on the 12 ... I'll post pictures but they are not very informative ... just wires all over the place.

Van's Aircraft came out with an auto pilot for the -12. The kit sells for $1950.00 ... and can be installed either now or after the plane is completed. Guess I'll wait.

Gas Tank & Wiring ...What a Combo!

2009-10-26T21:28:00.005-04:00

Still working my way through Section 31 , The Fuselage Wiring Harness. I made it to section 31-04, step 6 and ran into a problem. One of my CPU fans was not working ... so I called Van's Aircraft and they sent me out one at no charge ... I just had to wait for it to arrive so I jumped ahead to section 37 and tackeled the fuel tank while waiting for the fan to arrive.

I tried to be as neat as I could while working on the fuel tank but that sealant is a mess to work with ... no if ands or buts. I had the MEK solvent, latex gloves, rags, sealent from Van's in the caulking tubes, Van's caulking gun and popsicle sticks all laid out and ready to go ... and still it was a mess to work with. I completed the front half of the tank and then ran out of the sealant so I had to order more from Van's.

I didn't want to start a third section so I decided to wait for either the fan of sealant to arrive. A new CPU fan arrived so I continued with fuselage wiring harness. I made it to section 31-6, step 3 ... and so far so good ...

By the way ... there are now 7 RV-12s that have put air UNDER their tires ... I'm jealous ... but my day will come ...

Began Wiring Today

2009-10-16T18:16:00.011-04:00

With the fuselage on it's side, I was finally able to attach the clip holding the return fuel line to the interior of the firewall. After finishing that, I began the wiring process.

When you pull the telephone line through the 1202Y conduit tube you might try taping the clip so as to hold the clip close to the wire (section31-3) ... this will facilitate pulling process with the pre-set string.

So far I ran the WH-RV12-SL-ANT, WH-RV12-TX-ANT the ES RS 279-374 Phone Cable. That went smoothly enough ... but you do have to loosen the rudder pedals to pass the wire tips over the rudder pedals. Also, when you slit the snap bushings to make the wire fit thru, it's best to cut them on the top and bottom of one of the side slots so you only have to cut a couple of very small bits of plastic. I cut the snap bushings with my aluminium shears ... no problem.

Van's Aircraft website currently lists 5 (five) RV-12s completed and flying. To date there are 6393 Rv's completed and flying ... click here to see the latest first flight write-ups!

Flipped Fuselage on Side ... Hurray!!

2009-10-15T14:06:00.004-04:00

Believe it or not, today was a big day! I was fortunate enough to get three neighbors and my wife to help me flip the fuselage-tailcone on it's side! I can reach areas in the cockpit that I could never come close to reaching before. I hope now to make some real progress on the finishing kit ... finally!

Yesterday before the flip, I debured & painted the 7 main access panels on the floor and behind the luggage compartment. I learned from experience to never, NEVER spray paint while in the hot sun ... I guess it dries too fast and doesn't adhere to the metal.

Back from OR & CA ... now back to building!

2009-10-07T13:36:00.004-04:00

I spent the last month in Oregon visiting my daughter, son-in-law and grandson. We all had great fun visiting Crater Lake National Park, Medford, Klamath Falls, Newport and last but not least SanFrancisco. The entire trip out West I was thinking about my RV-12 and how much full it'll be flying out there in it next year. That's right this baby will be in the air sometime next year ... by July, I hope.

I just installed the 1204Y plastic conduit tube and now need to find a couple of strong guys to help me turn the fuselage on it's side to continue. Will be 100% back into the project in the next couple of days.

A fellow homebuilder has FINISHED his plane and has flown it. Congratulations to him and if you would like to see his plane and read all about it click here!

Cowling Done ...well almost, anyway

2009-09-01T16:26:00.006-04:00

I'm just about finished with the Cowling Section 38 ... upper and lower cowling match up as good as I can get'em. Just remember to apply a little Boelube oil to the hinge pins before you try to slip them into the piano hinges. Check and double check the hinges before you rivet them to the different areas of the cowling ... you'd hate to make a mistake there.

By the way, my wife came out to the garage last week and saw me searching for the cleco pliers, screwdriver, cleco and just about anything that wasn't screwed down ... she suggested I get a tool belt. What a great idea! I never thought of that. I went to Harbor Freight and bought a tool belt for about $7.00. What a good investment! Everything I need hanging

around my waist.

I've decided to leave section 38-09 steps 2 thru 10 till I'm finished with the entire Finishing kit. Will also leave the majority of section 30, Fitting the Wings, undone till I get into a hanger. So tomorrw I'll continue where I left off on Section 31, Fuselage Wiring Harness.

The oil access door tool about five hours to do. As I've said so many time before, I'm not the fastest builder in Van's World ... but I'm getting the job done.

Getting the HW 2600-3W camlock fasteners into the upper cowling to place the HW 212-12 camlock receptacle in their proper position was a bit tricky till you figure out you have to put pressure on the camlock fasteners so they will fit into the 1/4' hole in the cowling. Difficult to get them in & difficult to get them out ... but doable with thunb pressure on the HW 2600-3w fasteners.

Here's a video of my RV-12 build after 720 hours ... feel free to take a look. Click Here!

Cowling takes a while ...

2009-08-29T18:55:00.008-04:00

Still plugging away at the cowling. I'm trying to be careful not to remove too much material and be sorry. I went to Home Depot and bought some additional 80 grit sandpaper to trim up the edges of the cowling. A few more hours and I should begin wiring the Rv-12 ... looking forward to that.

I gave a talk about building my RV-12 at my EAA chapter meeting Wednesday, August 26th. I had about 65 slides shown in a Power Point presentation ... took about 35 minutes and I think the audience found it interesting.

The 3 pictures of parts comprise the remainder of my finishing kit ... plus the canopy of course.

I'll guess some RV-12 builders will be airborne within a couple of months since all the kits are finally available ... stick with me ... I hope to be in the air by next summer.

I'm Back At It ...

2009-08-21T14:07:00.004-04:00

I haven't worked on my RV-12 since July 8, 2009 ... for personal reasons ... but I'm back now and hope to put a dent in my Finishing Kit.

I received the new pin stopper (WD1217D) I destroyed last month ... tapped it properly this time, set in the magnet & applied the epoxy. All taken care of.

Now that I've riveted the tailcone and fuselage together, there's not enough room in my 2 car garage to fit the wings on as stated in section 30-02, step 8... so I'll have to wait till I get a hanger. In the meantime I'll continue to work on cowling & pick and choose those sections I can complete in my garage.

I've fallen a bit behind ... hey, wait a minute, it's not a race. But I did order the wing kit, fuelage kit, tailcone kit & the finishing kit on the first day they were made available for purchase. Now the avionics kit and engine kit are being offered and I haven't ordered either one yet. I'll get there eventually!

I placed the seats in the cockpit and the canopy frame & canopy onto the fuselage for a photo opportunity. Personally, I think it looks pretty good. I can't wait till she flies.

Cowling Hinges

2009-07-02T21:02:00.013-04:00

So far not very difficult but

very time consuming.

Section 38-03, step 3 confused me

I called Van's builder's assistance. There was no part number listed for the left & right cowl hinge pin. It looked like a regular hinge pin in the plans but with a rectangle with a hole in it. I was told a left and right Cowl Hinge Pin came with the kit and it looks exactly like the drawing, with the rectangle and hole ... a generic item used on most of the RV's. I found it! Wish all my problems were that easy to solve.

Section 38-04 has a note on top of the page: Mark hole locations on the outside when installed as shown in figure 3. Important to follow or you may have to remeasure and mark ... not a big deal, just save yourself the extra work and follow the note.

Another day, another rivet ...

Started the Cowling ...

2009-06-29T18:57:00.016-04:00

I left section 30 behind till I get a new fuselage pin stopper and grommet.

I tackeled the F1270B assembly (section 31-02, steps 1-5). No problem!

Then in section 31 (the revised section 31-02, revision 1) step 6 calls for an AN931-4-12 grommet to be modified in step 6 on the 6/23/09 revision ... not in kit ... so I ordered 2 (in case I break one, not unlikely).

I skipped sections 30-37 and began section 38:Cowling. Section 38, step 1! Figure 1:Trimming the Top and Bottom Cowling ... I correctly decided not to remove material to the scribe line in the bottom cowling around the semi-circle where the prop protrudes and two inboard areas adjacent to the semi-circle where there are no hatched areas indicated. I didn't see a scribe line ending the top of the bottom cowling from side hatched removal of material to front adjacent non hatched area. So I followed the curve of the inboard top of cowling and arched it down to scribe line on upper sides.

Again, I just removed the hatched area and drew an "imaginary line" connecting to the front unhatched area ... Call Van's builder's assistance, to be sure, before you mess up this expensive piece.

To cut the cowling I uses my Dremel tool with a cutting disc attached. Do wear a dust mask and eyeware protection. I broke several disks and pieces went flying. Had I not worn the safety eyeware I definitely would have had an eye injury! Safety first! Be careful and protect your eyes and lungs!

Also my fuselage and attached tailcone is upright on 3 short homemade sawhorses. Other builder's on VAF advised me to set the fuselage assembly on it's side to facilitate the building process. As soon as I round up a couple "volunteers" the fuselage assembly will be laid on it's side.

I was hoping to be flying my RV-12 by Xmas '09 ... now I'm guessing July 4th. of 2010 ... I'm not the fastest builder out there! I still think the RV-12 is a Great Kit ... it'll be done when it's done. __________________

Finishing Kit ... Off To A BAD Start!

2009-06-25T21:43:00.016-04:00

Page 1, step 1 (section 30-02, step 1) of the finishing kit and I totally messed it up! I've still got a lot to learn! Step 1: Tap the hole in each of the WD-1216C Fuselage Pin Stoppers as shown in figure 1 (tap for 10-24 screw). I had no 10-24 tap with my Avery RV-12 tool kit so I drove to Home Depot and bought that tap for $5.00. My first tap was very tight and I didn't make it fully thru the pin stopper. On my second try the tap cracked in half deep in the WD-1216C Fuselage Pin Stopper. $%&#@! I hope to salvage one of the two pin stoppers and so far ordered one new one ($8.50). I'll need to buy another tap too.

Minutes before, I tapped the holes in the roll bar for the aft window with no problems (on 25-05 step 5, revision 1/20/2009 the revision has you final drill #36 all the holes in the roll bar before tapping 6/32 screw holes (old replaced version doesn't say to final drill # 36 before tapping ... I would have messed that up to if it weren't for the revision ... hmmmm). Wish there had been a new version for page 30-02, step 1 stating to drill holes with a #25 drill bit before tapping the WD1216C ... I learned that lesson a bit late.

So far my build hours are as follows:
Wing Kit Completed: 232.5
Fuselage Kit Completed: 314.5 hours
Tailcone/Empennage Kit Completed: 151

Total so far: 698 hours

Oh well, better days ahead, I hope.

Tailcone Riveted and Rear Window Clecoed

2009-06-19T21:26:00.005-04:00

I'm so close to finishing my fuselage kit ... so close ... maybe one or two more days and then on to the finishing kit.

When riveting the F1284-L & R shear clips to the fuselage, be careful that they match up and there is no space between those tailcone shear clip and the fuselage attach points (section 25-04, step 1). You may have to reach thru the nearest lightning hole, nudge the shear clip to match the rivet holes.

Clecoing the F1277L & R turtle deck skins takes some patience. At first the holes wouldn't match up ... so I took all the clecoes out and started again in a different pattern and voila ... they matched up.

I'm taking Marty S's advice ( Marty's RV-12 Blog ... click here) ... and not riveting the F1277L & R turtle deck skins till later in the building process. That should facilitate control cable assembly, gas tank installation & attaching the aft window (F1277A). Thanks for that advice Marty.

Once I start the Finishing Kit, install the tricycle landing gear, inflate the tires, place the scarlet red and light gray seat cushions in the fuselage and attach the seat belts, I should be able to actually get in the RV-12 and make airplane noises in my garage. Yippee!

Tailcone Clecoed to Fuselage!

2009-06-12T19:08:00.012-04:00

My RV-12 finally has one long beautiful fuselage ... not a Boeing 747 fuselage, but a fuselage none the less.

In section 12, page10, steps 1 thru 6; attaching the nutplates to the aft of the tailcone assembly to screw the tailcone fairings (F1294 assembly) into place took me 5 hours to complete. Six steps ... yet so time consuming. I didn't have an extended #40 drill bit so I bend the K1000-6 nutplate in the opposite curvature they would be permanently mounted to the inside of the tailcone and temporarily clecoed them to the outside curvature of the tailcone and match drilled (#40) the tailcone and K1000-6 rivet holes. Then bent the nutplate curvature of the K1000-6 platenuts 100% opposite of the way they were on the outside of the tailcone for the riveting and made them fit the inside curvature of the tailcone. Great suggestion from a friend. Guess this is a good time to once again repeat:

Remember, I'm a newbie builder. Be sure to check with Van's Aircraft Builder's Assistance before following my lead in any building procedure, method or anything I do or suggest . I've never taken a builder's course nor do I have any experience in building an aircraft. I'm the furthest thing from an expert builder there is. So reader beware ... and refer to my site with caution!!

That said, my clecoed tailcone & fuselage looks fantastic. Be sure to have a helper when attaching the tailcone assembly to the fuselage. One person should be sure the tabs on the forward upper section of the tailcone (F1279L & R, F1278) clears the baggage bulkhead(F1207c L&R and the F1207A). Be careful not to bend any tabs while fitting the two sections together.

I'm getting closer to starting finishing kit!

Tailcone, Rudder & VS Fairings

2009-06-02T19:59:00.008-04:00

The tailcone fairings were a bit tricky until you get the hang of it. I trimmed the rudder fairing (R-1206) and the vertical stabilizer fairing (VS1213) with the scotchbrite wheel on my bench grinder ... worked great, like a hot knife thru butter. Just take it slow and be careful not to trim off too much.

The tailcone fairings (1294A & B) were easy to trim with my Dremel and a cutting disc. Once again go slowly. At first I tried cutting away the extra material with a hand shear, scissors, kitchen sissors and tin snips ... not great results. The Dremel did the trick. This was the first time I used my Dremel cutting blade and it splintered and sent pices of the cutting disc flying. I was lucky that I was wearing glasses. Remember to use the safety goggels supplied with the Avery RV-12 Kit. Lesson learned!

On page 12-07, figure 1, look closely at the locations for the 1294C tabs. I drilled 3 #40 holes on the lower ledge of the 1294B lower tailcone fairing before I realized the tabs go on the upper ledge. Oh well, shouldn't be difficult to fill those 3 little holes with a touch of fibreglass "stuff" when I get to the canopy. Read and reread the plans. Think Jerry, think! Lesson learned!

The 1294C tabs have to be separated, deburred, match drilled to the 1294B lower tailcone fairing, attach a nut plate, enlarge screw hole to a #27 modified bit and then riveted and screwed. I didn't have a #27 bit ... so off to Ace Hardware, then modify the bit by drilling into concrete 1/8" ... then enlarge screw hole for K1000-6 (AN526C632R8) ... that's when I drilled a #27 hole into my right index finger ... ouch! I used too thin a piece of wood behind the hole for support. My fault, lesson learned!

I don't think I'll be in the air by Christmas 2009 like I had hoped. As I've said before ... I'm not the fastest RV builder. I received my Finishing Kit on May 19th. ... but not quite ready to start on it. Couple or three more weeks, I think. No big deal, I'll be done when I'm done.

SCRATCH

2009-06-02T18:27:00.006-04:00

Documentation of scratched canopy during delivery .

Panel; Map Box; AST Motorized; Fibreglass Fairings

2009-05-27T17:50:00.012-04:00

I decided to use rivets for my center section of the panel even though Van's gave us the option to screw it on with nuts and washers. I hope I won't regret that decision later in the build ... time will tell.

I thought the map box was going to be an easy process ... I was wrong. No matter how I tried to get that door to open the full 90 degrees, I couldn't accomplish that feat. Don't laugh but I spent over 6 hours in an attempt to do it correctly and get the full 90. When all was said and done, I achieved a 65-70 degree opening. I made several shims of different thicknesses of aluminum scrap, placed them alone and in different combinations between the hinge and door panel and I fudged the rivet holes on the inside of the map box. No luck no matter what I did I couldn't achieve a full 90 degree opening. After I riveted it together it was pointed out to me that had I shaved off 1/16" off the entire bottom of the door (not stated in the directions) I would have had no problem (maybe a slight gap). On VAF someone suggested the 3/8" from door hinge rivets to bottom of door in the plans should have been 5/16". That was his suggestion and now I agree ... you'll see what I mean when you tackle the map box. Good Luck.

Oh yea, I was trying to build the map box while it was clecoed to the panel attached to the fuselage. Wrong. Put the panel and mapbox on your work bench, complete the mapbox riveting and all then cleco the map box panel assembly to the fuselage. I never said I was a genius. Van's builder's assistance pointed that out to me (not that I wasn't a genius but I should do the work on my work bench)... thanks ... that made it much easier!

I needed to locate a 12 volt battery to operate and check clearances of my AST by operating the motor. After searching for a 12 volt battery at Target, Wal-Mart and Home Depot, I finally located one at Radio Shack for $3.99 (clearance) and bought some alligator clips to simplify the process. That little servo motor worked fine.

Also the camlock on the map door lock was a bit too short since I had my panel powder coated. I filed the camlock shorter and it fit fine. I felt like a dentist making a crown ... and believe me, I' m no dentist.

Since I had my 3 panel sections powdercoated, I had to grind down the edges of those panels to successfully screw those 2 panel pieces on. A simple job of screwing the 2 panel to the fuselage took me more time than I care to admit. The last 2 screws were a trick to line up with the platenuts ... just had to loosen up several of the other screws and bingo ... all's well that ends well.

So far no problem with the fibreglass fairings ... fit nicely on the rudder, done ... hope the remainder of the fibreglass work goes as smoothly. Wouldn't that be nice.

No work on the RV-12 today ... went flying with a friend today in the Sport Cruiser ... what a nice aircraft. If I remember correctly from my demo ride in the yellow RV-12, the RV-12 will fly just like that Sport Cruiser ... no complaints there!

Finishing Kit Arrives ... not quite ready

2009-05-19T13:23:00.008-04:00

This morning after shifting around the fuselage and tailcone in the garage, I was able to make enough room for the delivery of the Finishing Kit. It is very, very tight in my two

car garage. How some builders are able to build an RV in a one car garage is beyond comprehension.

Only 2 fork lift holes punched through the sides on the shipping crate ... low and not too deep I hope. I'll know more when I inventory the kit in the next couple of weeks. Not worried ... I'm sure Van will make it right if there is some damage.

Delivery can be seen by clicking here, and here and here ... got to warn you, not very interesting. If you're a potential builder you might just want to see the size of the crate.

Back to building tomorrow!

Anti-Sevo Tabs are Attached!

2009-05-18T17:36:00.005-04:00

Both AST (anti-sevo tabs) assemblies have been attached with the two fabricated hinge pins as instructed in section 11-04 step 2. There was very little tolerance between the two assemblies ... I found it necessary to use my scotchbrite wheel on the Dremel tool where the 2 inboard tabs touch to allow the two AST's to fit. Just a light brushing with the scotch brite wheel on both tabs was all that was needed. It was also helpful to use Boelube on the hinge pin to ease the insertion.

When fabricating the F1287G aluminum tube, the plans call for a 1 15/32 length ... I found that a bit long and need to grind it down a bit to fit into position. Not a big deal ... just hard to get up from laying on the floor several times to grind it down ... on the brighter side it was good excercise.

In section 11-08, step one it calls for a 12V DC battery pack from a cordless drill ... unfortunately I have a 24V drill ... so I gotta find someone who has a 12V drill. Silly little problems like this are so time consuming ... c'est la vie.

Speaking of silly problems ... I picked up my map box door from the powdercoater ... remember, I forgot to have it powdercoated with the rest of the panel. I'm pleased I got the door done too ... it's going to look great.

The RV-12 shirt pictured above was purchased at Van's booth at Sun 'n Fun. The embroidered shirt has my N-number ... N124JG ... I imagine the shirts can be ordered online at Vans Aircraft.

With a Little Bit of Help from My Friend ...

2009-05-13T17:36:00.009-04:00

The stabilator, vertical stabilizer and rudder are temporarily attached to the tailcone. It's finally looking like there's an airplane is in my garage. My first kit, the wing kit, was delivered on May 9, 2008 ... about a year ago today. My fourth kit, the finishing kit is due any day. I should complete the tailcone/empennage kit & the fuselage kit in the next 2 weeks ... then inventory the finishing kit within 30 days of it's delivery and then begin again ... Finnagan. After which I order and complete the engine kit & avionics kit ... then go flying and check out that RV grin I've been reading about.

I'm still waiting for the map box door to be powdercoated ... should be done sometime this week.

Mounting the rudder & stabilator takes two people and if one of those two people is an recidivist RV builder so much the better. My friend, pictured above sitting on the floor beneath the rudder is the same fellow who taught me the use of most of the aviation specialty tools, helped me with the baggage floor (bucked the rivets), worked with me on those %&!@# longerons, assisted me with the brake and fuel lines, flipped my wings every so often, made interior painting recommendations and so much more. He's always avilable to give me encouragement, suggestions and a helping hand. A newbie builder would be wise & fortunate to have a friend like him to facilitate the building process.

Upper Forward Fuselage Skin & Panel

2009-05-08T19:18:00.008-04:00

With the upper forward fuselage skin (F1240) and the three black wrinkle powdercoated panel pieces (F1202U, F1202A,F1202T) clecoed to the "canoe", it's begining to look like a cockpit of an aircraft. Finally

I'm working on the glove box kit and low and behold I neglected to get the map box door powder coated ... so I made a trip to the powder coat facility and for $15.00 and a week's wait I'll have my door powdercoated. I've also decided to paint the map box interior and exterior the same gray I used on the cabin interior.

Almost done with section 29 ... then I assemble the fuselage kit to the tailcone/empennage kit and work with the tailcone fairings.

Finishing kit will arrive next week.

So Far: 612 Hours Into RV-12 Build

2009-05-04T19:06:00.025-04:00

If anyone is interested... 232.5 hours to complete the wing kit; 272 hours to build fuselage as seen above (including interior painting); & 108.5 hours to build tailcone and empannege ... Total Hours to date: 612 Hours.

Still need to attach and fit rudder and fiberglass topper, vertical stabilizer and fiberglas topper, stabilator, anti-servo-tabs & fit & attach 2 piece fiberglas tailcone pieces to complete Fuselage Kit and Tailcone/Empennage Kits before arrival of Fnishing

Kit.. HELP!

In my defense, I never took a builder's workshop or have had any experience in any type of building, construction or reading schematics ... Guess I'm doing O.K. afterall!

I finally riveted the Panel Base Assembly to the F1201A upper firewall ... a few small adjustments later it fit fine. The panel ribs (F1202H R&L) are riveted on to the longerons, upper firewall and the 2-F1202Y angle extrusions which I had to fabricate twice to get it right, are securely riveted in place and ready to act as the fulcrum for the soon to be received canopy frame.

Fuel line complete except for MS21919DG4 clamp on firewall securing vent line ... can't reach far enough into the fuselage ... will be able to secure that clamp when I actually get into the fuselage once landing gear and wheels are attached.

Section 24 has been completed! The roll bar brace (F1232A), the two brace brackets (F1232B L&R),baggage side bulkheads (F1207C L&R) & top baggage bulkhead (F 1207A) went on with no problem ... smooth sailing!

I'll need help (2 person job) to work on section 25, Tailcone Attachment. But that's nothing new ... I need a bit of help every so often as those of you following this blog know. It's good to know someone who has already build an RV or two!

Back to the Fuel Line

2009-04-28T20:35:00.004-04:00

Spent the morning making four little sawhorses so I'll be able to connect the tailcone to the fuselage and have somewhere to support the whole thing. The 3 hours it took to complete that task WAS NOT added to my build time for the day. Spent another three hours with my friend, the recidivist RV builder, who helped me with my fuel lines ... and 2 hours working alone on the panel base assembly.

We were able to assemble the fuel line and vent line from the rear of the fuselage to the fuel pump, attach split rubber hose and three clamps as seen above. Finally ...

Tightening the AN837-4D fuel line connector passing thru the rear main bulkhead on page 28-06 was fairly difficult to accomplish. Just had to crawl under the fuselage, use a very short cresent wrench, slip in in access hole in bottom of fuslage ... and turn it a bit to tighten. With luck, tomorrow I'll be able to bend and attach the forward fuel line vent thru 75% of the forward fuselage and then that'll clear the way for the riveting of the panel and panel shelf.

Took a few minutes to figure out how to get a flare on the rear end of the long vent tube ... just slip it to the back end unflared ... shove it thru the bottom access hole an extra 10" or so, add the nut and associated blue AN819-4D, use the flaring tool and then slip it back the extra 10' and then tighten blue nut ... Ithink. I'll know tomorrow for sure!

Back to the RV-12 Build

2009-04-27T20:46:00.004-04:00

I resumed my build today and actually got something accomplished ... I'm Baaaaack!

The first picture is the reason for my five week delay. But it was a great, fun delay.

I worked on the panel base, panel ribs, panel rib doubler, assorted nutplates and match hole drilled the longerons to match the panel base.

Tomorrow I plan on making four 15" sawhorses to set the fuselage and tailcone on, finish the fuel lines and continue to complete the fuselage.

It's great to be baaaack!

Interior Painting Done ...

2009-04-04T19:45:00.005-04:00

I know it has been a while since my last post. My 2 year old grandson is visiting with his mom and dad from Oregon. I haven't had time to work on my RV-12 as much as I normally would over the last 2 1/2 weeks ... but my wife and I have been having a ball with the little one!

Spent about 5 1/2 hours today finishing the interior painting. Just need a second coat on the F1232A rollbar brace and that, I hope will end my interior painting. The different paints I've been using have various times between coats. The Rustoleum primer allows a second coat within 1 hour or after 48 hours. The Krylon Fusion spray paint allows a second coat within 24 hours or after 7 days. I was unable to apply the second coat within the 24 hours ... so I had to wait a week to continue!

After my compressor and sprayer created a disaster with the can of Rustoleum Primer (last post), I then proceeded to the Rustoleum spray cans in gloss gray. The first coat looked terrible!! Every imperfection showd and called attention to each and every imperfection. I was really unhappy. I roughed up all those glossy sufaces with my scotch-brite pads and elbow grease and then searched for days for a satin gray in spray cans. I settled on Krylon Fusion sold a hardware stores and at Wal-Mart (just not in my color at Wal-Mart). The Krylon Fusion says FOR PLASTICS in large letter on the can. But if you read the small print it states for use inside or out on most plastics also great for wood, metal,ceramic and more. Label says, NO SANDING or PRIMING. The interior came out great with this stuff. When I used it on the other interior parts, like the F1207 D-L & R, F1207A, F1207C L& R, I just roughed the metal up with the scotch brite pad and used achemical to promote adhesion ... skipped the primer and sprayed away. All seems fine ... time will tell.

I can barely walk in the garage since I moved all parts from the guest bedroom and bonus room into the garage. (I didn't feel comfortable having finished assemblies within reach of an energetic, inquistive 2 year old.)

Still a lot to accomplish before my finishing kit is shipped the week of May 5th.

Section 10 Complete

2009-03-13T22:06:00.009-04:00

I've been without a computer for two weeks ... that's why no posts have been made recently ... but I have been working on my RV-12. So not only did I have to purchase my Finishing Kit (ordered 3/2/09, delivery expected mid-May) but I had to purchase a new computer. OUCH

I finished Section 10: Tailcone ... and took two steps back and had to move on to priming the interior of the fuselage (after my brake /rudder pedals were previously installed ... I taped and covered with paper the stainless steel firewall behind the pedals and those two areas will reamain unprimed and unpainted). I had primed the rollbar before riveting it to fuselage and I had honestly thought I was done priming it. WRONG. I bought the Rustoleum Primer for aluminum and used the paint sprayer that came with my Husky Compressor ... BIG MISTAKE. I constructed a paint tent from plactic sheeting and draped it over my chain drive on my garage door opener so the paint overspray would be contained. THAT DIDN'T WORK. Half way thru painting the fuselage interior the paint shot out of the sprayer like it was a Super Soaker water gun, the plastic sheeting blew all over and touched the painted surfaces and the primer I used on the rollbar peeled off like a banana skin (I neglected to scratch it's surface prior to priming). Needless to say I was very unhappy

It took 3 1/2 hours to strip my rollbar to the bare metal. I then buffed the rollbar with a scotchbrite pad ... treated it with a chemical to promote paint adhesion and the primed it with an oil based Rustoleum primer from a spray can, after which I sprayed the rollbar with a red Rustoleum enamel. It came out fine! I'll apply a second coat of red tomorrow.

The interior of the fuselage came out fine after I cleaned up some of the excess primer from the aluminum. I plan on covering the primer on the fuselage interior with a gloss gray Rustoleum enamel ... with individual spray cans, thank you ...

The paint tent is gone ... much easier to open the garage door, let in fresh air in, cover the driveway and walls from over spray and use those individual spray cans ... much, much easier for me.

Tomorrow I'll prime and paint the F1232A rollbar brace, F1207C-L & R and the F1277L & R turtle deck skins before they are riveted to the fuselage. Then all I'll need to do is finish section 24 ... from 24-04 step 1 to the end of that section, start and finish section 11: empennage attachment and section 12; empannage fairings by mid-May and I'll be in great shape to receive kit #4 ... the finishing kit.

The powers that be at Van's Aircraft are hoping to get the remaining engine kit (#5) and the avionics kit (#6) out befor Oshkosh '09 in August and hope some builder's might even fly their RV-12s to the event. Guaranteed I won't be one of those completed builders ... if indeed there are any completed RV-12s by August of 2009. At one time I had hoped to finish my aircraft by Christmas of '09 ... I'm now thinking spring or summer of 2010. Whatever will be will be ...

Tailcone taking shape ...

2009-02-27T07:57:00.006-05:00

While I'm not breaking any records for a speedy build ... I am making progress.

So far the tailcone skins are relative easy to secure to the J-stiffeners on the F1208, F1209 & F1210 cutouts. Just remember to slip all the J-stiffeners into all three cutouts at the same time.

I left the tie wraps loose as the note on 10-08 states ... guess more will be added under those ties with the finishing kit.

Also on page 10-08 , step 5 ... when you string the WH-P30 Trim tab electrical wire ... be sure to string that wire so the end with the brass pins are forward and the plain wire ends are aft. On my copy of the instructions it doesn't state that fact but it should ... and probably will soon in a future revision.

The finishing kit will be available for order on March 2nd. I'll order it then ... but ask for a delayed delivery date so I'll have time to finish both the Tailcone/ Empennage and Fuselage kits ... as I said, I'm not breaking any records for a speedy build.

Tailcone Bottom Shaping Up

2009-02-22T19:57:00.005-05:00

Tailcone bottom is shaping up. The bottom assembly of the tailcone is going together smoothly. On page 10-06, step 7 ... when it suggests you place the F1282 L & R bottom skin on sawhorses that are at least 38" tall ... take heed ... that's important in my opinion. I had to run out to Home Depot and buy eight 8X8X8 cinder blocks ($1.46 ea.) to set my sawhorse on to gain 8". It made it almost simple to assemble the F 1208, F1209 & F1210 frames onto the bottom skins. When attaching the F1281R & L lower skins, I just leaned the working edge down along the side of the sawhorses. When I worked on the second lower skin I just proped up the clecoed edge on the sawhorses and let the working edge hang over the edge while clecoing it.

Be careful on page 10-07 ...
study figure 1 and know what to rivet and more importantly, what not to rivet.

I did not rivet the F1281R & L lower skins to the F1208, F1209 and F1210 frames ... as per instructions (interpolated the facts). I'd rather make an error on the side of caution ... 'cause I hate having to drill out rivets!

I temporarily skipped section 10-05, steps 1 & 2 ... fitting the F1211 assembly to the stabilator because it is stored in the bonus room. Tomorrow I'll ask my wife, nicely, to help me carry it back into the garage for its fitting (washer determination) ... then carry it back to the bonus room ... my factory is getting smaller and smaller.

Stabilator Done & Into Tailcone!

2009-02-19T18:05:00.006-05:00

I finished the stabilator and progressed into the tailcone as far as section 10, page 4. step 8.

Be sure to cleco the entire F1210B plate and the F1210 C angle to the F1210 A-R & L fuselage frames before you rivet them together. Just remove the clecoes you need to allow the rivet squeezer to take hold. There seems to be a natural torque tendency to the fuselage halves and your rivets might not sit properly if not entirely clecoed. I know ... had to drill out 3 squeezed rivets ... be careful.

I was able to break all the edges of the tailcone skins with my Avery edge rolling tool ($20.00) ... just take your time and clamp the skins to your workbench while breaking the edges. If the skins aren't clamped down your edge breaking tool will not work properly. I know ... I had a problem with one of my fuselage skins.

I used my hacksaw to cut the excess angle material from the F1211G tail skid bracket ... it worked out fine. I placed the Tail skid bracket in my 6" vice and succesfully drilled the 5/16th. hole and to tap the 3/8 X 16 one inch deep. I followed a friend's advice and was able to do it with no problem.

Had a great day yesterday ... rented a Tecnam Super Echo at Lockwood Aviation at Sebring Florida ... watched the cars race around the Sebring International Raceway ... flew to Placid Lake and practiced some touch 'n go's in windy conditions. I seem to be spending so much time in my garage that I'm not getting in the air as much as I would like to. That's going to change ... more flying in the weeks and months ahead.

Still on Stabilator

2009-02-12T21:27:00.002-05:00

One more day on the stabilator ... then on to the tailcone. But I still have to finish the fuselage kit ... sometime. I skipped the sections of Van's instructions for those of us who did not yet have the tailcone. Unfortunately in that skipped section was the suggested point in time to paint the interior of the the cockpit. I installed my brake lines and the majority of my fuel lines before the interior paint job. So now I've decided to tape off the entire aluminum panels behind the rudder brake pedals (& tape off the brake and rudder pedals too). Who knows ... that might even look good. A little reflective aluminum in the cockpit just might look ... cool.

The third picture above is the result of section 09-08 step 2. Just for match hole drilling a few holes ... the hinges aren't mounted like that permanently ... just for the moment.

All the riveting went smoothly ... finally ... no errors.

Tomorrow I'll rivet the aft skin, HS-1217, complete the mounting of the upper and lower horns (WD-1207 & WD1208), insert the counterbalance arm ... and weights and then on to Section 10: Tailcone.

Even if the Finishing Kit is made available immediately ... I've decided to wait till I'm a couple of weeks short of completing the fuselage and tailcone kits before I order the finishing kit.

I plan on storing the stabilator in the bonus room, till it's called for later during final assembly. My manufacturing assembly area will then consist of the two car garage, guest room and bonus room. I hope my plant manager (wife) has no objections.

Stabilator stabilized ...

2009-02-10T06:41:00.007-05:00

I can't stress the importance of marking the HS1211, HS1202 & HS1203 forward, aft, up and down so you know exactly where you are in the building process. Also mark the WD1222 and WD1223 as well as the WD1207 and WD 1208. Mark everything. Also note the top edge of the WD1223 and be sure when you rotate that piece the Top Edge is at the top.

Carefully study figure 1 in section 09-03. Get a magnifying glass if you have to, I did ... and am glad I did. Only 2 0f the HS1209 spar caps go on top of inspar ribs ... the other two go ... elsewhere. Look closely. Also be sure to recognize the "closely spaced holes" and as always carefully follow the directions. There are multiple places to mess up if you're not super careful. Miracle of miracles ... I made thru that mine field with no mishaps.

Made Rudder and Anti-Servo Tab

2009-02-03T18:22:00.012-05:00

To be a bit more precise I finished the rudder and I am currently on section 8, page 4 step 1. (1/2 hour from completing the AST!)

The rudder progressed relatively smoothly. Interpreting figure 3 in section 7 page 05 was a bit tricky ... but important. Be careful and set the real article next to figure 3 and remember it's a TOP VIEW. Enough said ...

Building the anti-servo tab was made easier because of advice I received on Vansairforce.com. Click here for that advice ... it worked out fine . Thanks Big John. I riveted the AST control horn (HS1220 R & L) to the inboard ribs (HS1222) before riveting the entire combo pieces (HS1220 + HS1222) to the HS1221 L & R skin.

When using the HS-1223 drill guide, if it doesn't easily snap between the eyelets you might consider passing a file a couple of light strokes on the drill guide to make it fit a bit better between the eyelets. Remember to study figure 7 (section 08-03) before match hole drilling the hinge. Don't drill out all the holes on the drill guide ... just the 33 places on the hinge shown in figure 3! But never fear ... I ordered extra hinge material weeks ago in anticipation of making a mistake ... lucky me.

Onward to the Stabilator ...

Started Empennage before finishing Fuselage ...

2009-02-01T10:45:00.008-05:00

I still have to finish the fuel line and panel portion of the fuselage kit but since I was missing some rivets and had to wait for them to arrive from Oregon ... I decided to move on and start the empennage kit.

Getting the VS-1201 skin clecoed and then riveted to theV-Stabilizer Skeleton Assembly

was trickier than I thought it would be. Lining up the ribs under the skin was made simpler by using a thin metal meter stick to adjust those ribs so the rivet holes would line up and allow me to get a cleco in. After about 4 hours ... I was done. Phew ...

The completed aircraft in today's picture section is an Indusair Thorpedo LSA. I took the picture at the Sebring Sport Expo last month. I liked the paint scheme so much, I'm considering it for my RV-12. When I find out how much that paint job will cost, I'll probably opt for a single color and vinyl accents. We'll see ...

Still on fuselage kit ...

2009-01-26T18:19:00.009-05:00

With a bit of luck I hope to have the fuselage kit finished (minus the tailcone attachment) in a few more days.

The brake line was very difficult for me to complete. Once I boiled the ends of the brake line and inserted the inner sleeves it was near impossible for me to slip the ferrel and or nut down the line far enough so the female portion of the nut would connect to the male counterpart. I finally removed the line and placed the plastic brake line in my 6" vice lengthwise and made it just tight enough that the plastic line had no pressure on it and the nut was hooked on the end with no pressure on it. Then I pulled with all force I could muster and was then able to move that nut down the plastic brake line over where the inner sleeve was inserted ... then mated the end and tightened them down, finally.

The fuel lines were just trial and error. Since I couldn't make my 90 degree bend close enough to the end of the tube I made my line longer in some sections. The "matching" drain line/air intake line was made but not attached until I have the gas tank so I know if it matches up properly. If not a couple little bends should do it.

My kit didn't include the 14 AN426 4-5 rivets necessary to attach the F1202M R & L to the F1202H R & L canopy ribs so I let Van's know and they're sending them out.

The two F1202Y strut attach angles made from the two 1X1 2" angle irons were destroyed by my inexperience. My first attempt at making them I drilled the rivet holes and then the drilled fastening hole for the screw. Wrong! That didn't work. I ordered 2 more 1X1 angle irons then I drilled the fastening hole (screw hole) first ... screwed in the screw ... after that I drilled the rivet holes and it worked.

While waiting for the missing rivets to arrive and before I finish my last section of fuel line, I jumped ahead and began my tailcone/empannege kit.

Slowly but surely ...