The Delivery of the empennage kit goes easy with the fork lift. My son Timo Aringer is wondering: „what the hell is my father doing here….“
Inventoring all the parts took about 6 hours! I will try a method to find the parts later on by sorting them by their part numbers. The fist letter of the parts describes the kit position – so I thought this would be a good thing sorting them together (VS, HS, F, FL, E, etc.) Turns out to be a good method so far.
Empennage kit delivery
Empennage Crate opened
Van´s perfect packaging skills Timo is fascinated of
Frank bei der Inventur „fertig“
Ernst-Otto is inventoring the Empennage Kit
screws,rivets, more rivets
parts sorted and labeled
Next step: preparing some parts for the first start
Preparing the rear spar, deburring, straightening, final drill and match drilled some parts. Parallel to the deburring I took the training projekt (Vans Tool Box and the flap training kit). My friends Frank Goehner and Ernst-Otto Rehm are very helpful giving me hands to help at some difficult to reach places and by having fun with the build process. I´m glad to have them as friends – not only for some help :o)
Deburred all the skeleton parts of the vertical stabilizer, straightened the VS-1008 rear spar doubler, clecoed all parts together and final drilled all #30 holes. Peeled of the blue tape from the skins inside and on the outside only there, where to work on the prepunched holes with a straight edge and a soldering iron. Clecoed the skin to the skeleton and final drilled all the holes common to the skin, exept the holes for the HS and VS fairings. HS = Horizontal stabilizer, VS = Vertical stabilizer
VS-1003
vs reinforcement plate
match drilling
Clecoes – the magic thing
Bohrungen gesenkt für Nieten
Teile fixieren, dreimal auseinander und zusammen
rivet hole countersink
peeling of the blue protection
Radius schleifen VS nose rib
Helping hands
Ernst-Otto Rehm
Frank Goehner
Deburring VS parts
VS rear spar caps
VS-1008 reinforcement plate after straightening
19.01 – 24.01.2017 = 14,5h
Parts priming, Assembling the VS skeleton
Cleaned all VS Parts, assembled and riveted them together. I checked every manufatured rivet head for correct size with the rivet head control tool. To be able to run some wires through the vertical stabilizer for later use (i.e. Nav Antenna or similar), I glued a PVC-Pipe inside the VS Skin with a PU glue from Würth „Klebt+Dichtet“.
Primed with SEEVENAX Primer
VS-Parts ready for assembly
VS-Rear Spar before riveting
Rudder Stop bracket
Rudder Stop Bracket riveted
Gauge checking the set rivets
Diameter check = OK
Skeleton primed and ready for riveting
VS-Spar riveted
Vertical Stabilizer and Rudder Skins primed and ready for riveting
Cable tube glued in place
Würth „Klebt + Dichtet“
VS-Nose Rib Cut Out
VS rear spar doubler
Rudder hinge with rudder stop
Workshop head size check = ok
Workshop head hight check = ok
AN426AD4-7 flush rivets
Bottom rudder hinge with rudder stop striker plates
VS rib to spar rivet check = ok
18.02.2017 – 22.02.2017 = 12h
2017-02 Riveting the Vertical Stabilizer Skin to the skeleton with the Pneumatic Squeezer.
Before closing the VS Skin my building mentor Christian Tank came along and checked everything to be properly riveted and assembled and said: „Du baust sehr genau“ (You´re building very accurate)….what made me a little bit proud of myself 🙂 You also may want to see the Video down on the bottom of this page…
My building mentor: Christian Tank
Christian Tank is the CEO in the company, he took over from his father Wilhelm Tank. His company: Wilhelm Tank GmbH & Co Mariensiel KG Flugplatz 1 26452 Sande
VIDEO: How Frank and me do the riveting process together on the vertical stabilizer
Begin the riveting process my friend Frank Goehner was very helpful and we managed the riveting process really good together.
Clecos: Wer hat´s erfunden? Die Deutschen :o)
Der Nietprozess kann starten
All clecoes in place!
VS-Flush Rivets
VS-Top Rib
VS-Skin rivets checked = OK
VS-Spar Caps Rivets
Letzte Möglichkeit alle Nieten zu prüfen
Inside view VS vertical stabilizer
Rivet line checked = OK
Inside view to top rib VS vertical stabilizer
Frank with pneumatic squeezer
Middle rows of rivets ready!
Skin riveted
Rear VS spar riveted
Many rivets set, more to come…
Letzte Kontrolle vor dem Schließen des Seitenleitwerks
Letzte Kontrolle vor dem Schließen des Seitenleitwerks
Letzte Kontrolle vor dem Schließen des Seitenleitwerks
Christian Tank = Bauprüfer hat das Seitenleitwerk abgenommen. Jetzt kann ich es fertig nieten
Vertical Stabilizer start: 19.01.2017
Finished: 01.04.2017
Hours total: 26,5
Frank Goehner & Peter Aringer riveting the Vertical Stabilizer Skins
In this section you will see my self made (DIY) dimple frame DRDT-2 in his final version which I finally will use the whole building process. I am proud, that my version is functioning so far. Looking forward to use it for many times which will safe me a lot of hours!
Before putting them together, you have to prepare all the parts to fit together, so all edges has to be deburred, some parts have to be cut to almost smaler parts like the R-1010 Rudder ribs. This is taking a lot of time and sometimes a boring thing to do, but it is an essential work, because with this it is possible to ensure a long lasting airframe over many years of flying.
Dimpling the Rudder Skin
Selfmade Dimpletframe by Peter Aringer
Dimple detail Rudder Skin
Dimple detail row Rudder Skin
Dimple Frame with Squeezer
Dimpleframe head
Dimpleframe head detail
Rudder rib dimpled
Rudder skeleton
Rudder Skin scuffed with scotch brite pad
Rudder complete cleoed together
Rudder skeleton clecoed
Rudder Skin blue film removed
Rudder skeleton on the left skin
Rudder skeleton on the table
Rudder skeleton
Rudder cable arms
Rudder lower rib
Rudder parts ready for priming
Cutting instructions for the Rudder ribs
Riveting instructions for the Rudder ribs
Rudder Ribs befor cutting
R-1005 before preparing
Rudder rib parts
Rudder parts to be prepared and cut to size
Page 7-7 to 7-12 Riveting the Vertical Stabilizer, Rolling the leading edge, trailing edge finish
Now the exiting process of assembling all the prepared parts of the vertical stabilizer begins. When I clean the parts for priming, it is essential to mark the preped parts in the exact same way they were marked before!! At the top vs-rib I had a slight missalignment an had to fix this with drilling some new holes in the R-1008A and R-1008B top ribs. The whole process of riveting all the VS parts together turned out to be very exiting. The most exiting thing here was to bend the leading edge in a correct manner to not screw this up an make some niks in the skins while bending them.
Rivet check
VS spar
Backriveting
Backriveting finished
Missalignment
Missalignement fixe
VS spar doubler
Double flush rivets
Trailing edge very straight
Rolled VS skins
Counterbalance weight
Rudder Counterbalance Rib
Rudder metal work is finished. Some work to do on the upper and lower fairings on the rudder. Will return later on. 13.05.2017
Began with the Horizontal Stabilizer (HS). Prepared some Stock (edge deburring, flange straightening) and created two sets of cradles for holding the both HS halfes alligned.
Page 8-1 to Page 8-5 Started again with prepairing the edges, lightning holes and the powder coated HS-912 hinge bracket. Fabricated the HS-1008L+R left and right front spar attachment brackets, which are very critical regarding the hole spacing. As I had a dent in the VS skin I now agressivly rounded out the nose ribs and had no dents to the outside of the skin this time. Like in the plans I created the jigs for the horizontal stab skin to hold them upright positioned.
Rounding the HS rib shapeHS-905 HS ribsEdge deburringHS-912 powder coatedHS-1008-R+LFirst Horizontal Stabilizer assemblyFabricated the HS-jigs
Nach dem Entgraten aller Teile des Höhenleitwerks folgt das Bohren der Löcher auf Maß. Jedes Bauteil erhält dadurch seine zugeordnete Position. Anschließend wird nach dem setzen der Bohrungen jedes Bauteil hierfür nummeriert! Dann wird die Baugruppe zerlegt um alle Bohrungen von beiden Seiten zu entgraten.
Some photos of the horizontal stabilizer preparation and riveting process
Prepared the RV-10 parts for the elevator. Deburred all edges and holes. Clecoed all the sceleton parts together. Working on both right and left elevators. Frank is cutting the foam ribs for the trim rudder.
Beginning with the elevatorsAll the parts for the elevators are deburredElevator ribs clecoed togetherTrimm rudder foam ribsThe elevator sceleton begins to growCounterbalance ribElevator sceleton with the bottom skinAll elevator parts clecoed together for the left elevator
Sometimes I add a video, which I also post to Facebook or YouTube. Just for aviation interested people, who are following my project.
Video Elevator build start
Drilling or honing perpendicular is important!Honing the Elevator skin to the substructureMany clecoes are used hereRight elevator with clecoesCutting the trailing edge wedgeFitting the right elevator hornHoles have to be final drilled2017-06-29-23.27.09
