23rd February 2013

Center Stack

Just to give an idea of what the center stack will look like, I put the audio panel in place.


Hours: 0.2 | Posted in Foward Fuselage | 0 Comments

22nd February 2013

Instrument Panel

After getting a few things done in the hangar, I cut a length of 3/4×3/4×0.063 angle to length for the top flange of the instrument panel. Also 2 short pieces for the sides. Then I drilled 3/16″ holes at the right spacing and cut notches out with the band saw to match the holes. This will let me bend the angle to match the upper edge of the instrument panel.

Then I removed the instrument panel frame from the plane and started match drilling and forming the flange. Here it is essentially straight. Starting in the center and working towards the edges.


Here is the formed and fitted flange or angle, also match drilled to the top of the panel frame. Cleco’d to the board to hold everything steady while match drilling.


Then fitted and drilled the two little side pieces.


And test fitted back into the plane:


Wish I could replace the whole sub-panel, because of junk like what shows in the right edge of the photo:


Drilled and countersunk the side mounting holes for the instrument panel. The instrument panel is starting to take shape.


Hours: 5.5 | Posted in Foward Fuselage | 0 Comments

21st February 2013

Practice Riveting

To start out the afternoon, I need to get ready to do some real riveting on/in the plane. So far all I’ve done is external riveting using the hand squeezer or the pneumatic squeezer.

So I prepared a couple of scraps to emulate the skin of the aircraft and the floor stiffeners, the first area I will probably rivet. Then I got out my rivet gun which is a 3X model and an appropriate bucking bar.

The RV-6 plans call for an AN426AD3-4 rivet for these skins. So I used that rivet and tryed a few. It was a little hard as the pieces moved around, something that will not happen in the plane.

Here is the first practice. Probably more practice to come:



Hours: 1.0 | Posted in Foward Fuselage | 0 Comments

20th February 2013

Engine/Engine Mount

Worked all morning to finish removing the engine mount, about an hour apiece on the 3 remaining vibration dampers. It is definitely not a one person job. I had to make two special tools, and one difficult bolt took 2 arms and 1 leg to get enough torque to remove, leaving justĀ one leg to stand on.

But the negine mount is off now for inspection & refurbishing. I do have a brand new spare engine mount in the event there are any problems.

The engine with mount removed:


The old engine mount:


One of my ‘special’ tools:


Then my friend Howard showed up & wanted me to fly to lunch with him (C210). We decided on Greeley with the storm coming in. KFNL was still clear but turned out Greeley was getting closed in fast. Initially after takeoff on the way back we stayed low to stay out of the clouds & ice until we got higher ceilings in the Loveland-Fort Collins area.



Hours: 4.0 | Posted in Engine | 0 Comments

19th February 2013

Challenger Mockup

Spray painted the foam core mockup of the Challenger display & added an inkjet face to simulate the real instrument. Placed this on pilot side which is first intended use.



Hours: 1.0 | Posted in Foward Fuselage | 0 Comments

19th February 2013


Took a photo of the rear of the engine for future reference. I am going to remove hoses & old engine mount from the engine for inspection and refinishing or replacement depending on outcome of inspection & will use this photo for parts location.


Well after 3.5 hours of solid work, here is where I’m at. All hoses, etc removed. They will need to be replaced anyways as the plumbing is fairly different for the RV-7 versus the RV-6. Removed the nose gear from the engine mount. One vibration damper removed, working on the second. There are 4 of these. For the non-pilot, the engine is mainly held to the airframe by the outer 4 bolts. Naturally these are very special bolts.


Hours: 3.6 | Posted in Engine | 0 Comments

19th February 2013

IP & Sub-Panel Cont.

Yesterday was a consulting day, with work for Magnum Geo in Fort Collins on their VOIP phone system. So not much plane work yesterday.

Some time back I had asked for a bezel (only) for the Challenger display; but have not heard back. The Challenger display now appears delayed until summer 2013.

So in the meantime, in order to check clearances & fit; I built a foam core mockup of Challenger to use. Here it is in the panel but not painted yet & without connectors.



Hours: 1.0 | Posted in Foward Fuselage | 0 Comments

17th February 2013

Panel Bracing

I cannot use the old sub-panel to instrument panel bracing (F-645) due to clearance with the EFIS panels on each side. My little cardboard mockup of a new smaller brace did not work either as my tip-up canopy is the old style with the straight hinge pieces.

So I drew up a side view of all the pieces to show where I could put bracing without affecting anything. Can’t put the drawing in here right now as it is a pencil & paper sketch as I don’t have my technical tablet yet, so will have to scan it when I get home. Here is a photo version, better image will be in my sketchbook.


However, it looks like the brace will end up being a triangular brace made out of angle, connecting to the top & bottom of the instrument panel, and to the center (vertically) of the sub-panel. One brace on each side at the canopy hinge, skin rib positions.

Don’t know why I’m concerned about this brace. I suddenly realized I’ll have 2 stronger braces almost in the same location, called the sides of the center radio stack. So decided to go simple on any extra bracking. If needed, it will just be a pieces of 3/4″ angle. Here is a cardboard mockup.


And here it is taped in place at the rib/hinge location.


Heading home to make a hot glue mockup of Challenger since they are not available yet.


Hours: 4.0 | Posted in Foward Fuselage | 0 Comments

16th February 2013

Misc. Saturday

I received some platenuts I had ordered so I put the last 2 platenuts (corner type) on the rear brackets for the center tunnel.

The cardboard mock up of the small panel brace I sketched up will not work, due to interference with tilt up canopy pieces, so I am back to the drawing board there.

Won’t work:


Putting my rivets into parts bins and labeling them for easy access.

Working on the small angle pieces to brace the bottom of the sub-panel angle.


The two small brackets roughed up. Why are they different lengths? Because the original builder didn’t know how to measure.


Hours: 3.0 | Posted in Foward Fuselage, Tools | 0 Comments

15th February 2013

More Fitting & Sub-Panel Work

I cut a new piece of angle to go across the sub-panel bottom. It will be stronger and lighter than what was there before. Currently working on the bracing/mounting brackets for each side of this angle.

I did more test fitting in the areas of the sub-panel and instrument panel pieces. There are a few minor glitches but everything is looking good. This is only the upper panel pieces. There is a switches/controls lower panel not shown.

View from the right side:


View from the left side:


And with the lower switches/controls panel in the mock up.

Left side view:


Right side view:


This location & approach are what I plan for the bracing/support of the sub-panel bottom angle. It will just be a small piece of the same angle attached to both the angle and the F-602 bulkhead on that side, repeated on the other side. The pilot side may also have a small plate to mount the air manifolds for pitot and static air systems. Since both the sub-panel and instrument panels have a built-in tilt (approx. 8 degrees tilt), there is a small angle involved.


Hours: 5.0 | Posted in Foward Fuselage | 0 Comments