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Build Diary 2004

Build Diary 2006









Vans RV7 2005 Build Diary
After 20 months of building, G-OVII lifts off - 13:40 on 18th November 2006 - into the air for the first time. The sight was incredible as almost two years of work came together. Read all about it here.

Empannage Fitting
Just over an hour in the workshop tonight. Fitted the fuel and oild pressure block and sensors. Fitted the cable clamps, and cut two holes in the firewall for cables. Fitted AF-2500 to instrument subpanel.
Test Flight with Bob Cole at the controls
Riveted center section of instrument sub-panel in place, and refitted engine.
Empannage Fitting
Christmas is over, and Jo has got me lots of bits for my RV project and some tools - she is great. Topcoat painted the instrument sub-panel, panel brace and started to rivet it into place.
Test Flight with Bob Cole at the controls
It's the week leading up to Christmas, so my time is taken up shopping and Christmas parties. It the moment I am held up waiting for very small odd parts to arrive. When they do I then seem to find I am missing another small part - stopping me from continuing! However I have pushed on with painting the instrument sub panel as I want to rivet it in place and start fitting wiring.
Empannage Fitting
It's been a busy week, on the run-up to Christmas. Office Christmas party and work around the house has only enabled a few hours in the workshop. I have also been waiting for parts to arrive so this week I have been completing a few 'odd' jobs.
Test Flight with Bob Cole at the controls
Rather busy weekend - but not on the RV Project. Sunday removed engine and frame to work on the firewall. Also had to make some adjustment to the prop govenor.
Empannage Fitting
Working through the FWF parts to ensure they all fit properly. Fitted alternator - was suprised to find the Vans alternator is not a new unit. It appears to be reconditioned!! Have a look at the close-up pictures the rear casing is all bashed around and has been repainted. Looks really horrible on my nice new engine!!
Test Flight with Bob Cole at the controls
Contiuning work on plumbing the engine. Fuel lines, fuel pressure, oil temp sender and route of mag wiring. I have noticed a lot of the engine work will be held up - or cannot be varified as correct - until my cowels are fitted, which cannot be fitted until my propeller and spinner is fitted. I have decided to go for the Hartzell HC-C2YR-1BFP/F7496-2, supplied through Vans, its going to be 8 weeks waiting, the spinner they supply is fiberglass so I decided to see if Hartzell did one, they do - 836-60 or 836-60P. It will be metal rather than fiberglass. $1'874!!! Think I will be fitting the $160 fiberglass Van's one........
Empannage Fitting
After a disapointing Sunday this evening has gone better. I have done some research and have come a long way to resolving my engine fitting issues. I thought it was a good idea this evening to check the fitting of the exhaust as soon as possible in case of any issues, glad to say it all fits.
Test Flight with Bob Cole at the controls
Sunday - Not such a great day today. It started well when I decided to take the fuse out of the garage and fit the left wing. I have now discovered I have the wrong Fuel Injection Servo.
Empannage Fitting
Yet another big day!!! - Saturday, went to the airfield this morning. Far to much water about to fly so back to the workshop and fitted some parts to the rear of the engine then fitted the engine. I fitted it in under 2 hrs on my own!
Test Flight with Bob Cole at the controls
Another big day - offered up the engine to the frame to see were the controls may need to come through the firewall. All seems well so I have decided to put the fuse on it's wheels.
Empannage Fitting
Really big day engine arrived - Jade Air delivered my Superior IO-360 engine this morning.
Test Flight with Bob Cole at the controls
Refitted canopy this evening to check the space behind the instrument panel. Jo came and helped fit the canopy then we played flying........
Empannage Fitting
After a really bad week I am finally able to get back to my RV project. Building aeroplanes is far more fun than fixing house plumbing problems, especially when it involves the heating and it's in minus figures outside! I have finally planned what circuits to have on the RV, so I decided to continue the panel work by drilling the switches and circuit breaker holes. I also completed the map box. Fitted the throttle, prop and mixture controls. The shorter lead arrived from Advanced for the AF2500 engine monitor. Weather still bad, so it's just a few hours at a time in the workshop!
21st November 2005
Checked all brake pedal lines. Planned Instrument circuit braker layout. Didn't do much more it's 27F outside tonight - workshop is not much above that!!
Empannage Fitting
Today I decided to complete my parking brake. I have already made the bracket but needed some brake line parts to continue - so it was shelved for a while. The parts arrived with the firewall forward kit. As it's being mounted on the firewall and the brake lines come through the firewall I figured it was as good a time as any to finish the job. Even though I say so myself I am pleased with what I have done.
Test Flight with Bob Cole at the controls
Started work on the firewall. Fitted batterybox, master and starter relay's. Fitted various nutplates on firewall.
Empannage Fitting
The right wing is now complete. Again Jo came out and helped me pack it away into the roof of the workshop. Started on the firewall forward - battery box. It's really cold this evening so just an hour in the workshop.
Test Flight with Bob Cole at the controls
My firewall forward kit arrived from Vans. It's like Christmas has come early!! Jo came out to the workshop this evening and help move the wings around. I just have a few small jobs to complete on the right wing.
Empannage Fitting
Decide to wait for the firewall forward kit to arrive from Vans before continuing with the fuse work. I had been given a Duck Works landing light by another builder and finally decided I would fit it.
Test Flight with Bob Cole at the controls
9th November 2005 (Check)
Fitted left hub and wheel. It's really cold in the workshop this evening, so I didn't do much more. Ordered the firewall forward kit from Vans this evening.
Empannage Fitting
Decided to fit the landing gear on the engine frame today. Quite a big milestone the wheels going on for the first time.
Test Flight with Bob Cole at the controls
It's the week leading up to Christmas, so my time is taken up shopping and Christmas parties. It the moment I am held up waiting for very small odd parts to arrive. When they do I then seem to find I am missing another small part - stopping me from continuing! However I have pushed on with painting the instrument sub panel as I want to rivet it in place and start fitting wiring.
Empannage Fitting
Fitted brake pedal hydraulic lines.
Test Flight with Bob Cole at the controls
The fuel tap arrived from Andair this week so I have gone back to building the fuel pump assembly. This needs to have 5" of straight pipe in and out, so it's been a challenge to find a suitable location.
 
31st October 2005
Spent this evening fitting nutplates, dimpling and deburring the instrument subpanels and parts. Planned layout of circuit breakers on the instrument panel.
Test Flight with Bob Cole at the controls
Time to pull sub panel out and fit the engine analogue box to the subpanel. Spent the rest of the day fixing nutplates and deburring.
Empannage Fitting
The location of Advanced Control Systems (AF-2500) analogue control box gave me some challanges, originally I planned to fit it above the map box.
Test Flight with Bob Cole at the controls
Building the map box. Vans supplies an optional kit to fit a map box kit to fit to the instrument panel. I decided to fit the box for additional secure storage and I plan to fit the Advanced Systems (AF-2500) analogue control box on the top of the map box.
Empannage Fitting
Continued work on the instrument panel. Made mounting brackets for GPS, radio and transponder stack. Still trying to make my mind up about fitting the additional brace next to the Dynon D100.
Test Flight with Bob Cole at the controls
Worked on the instrument panel brace behind the Dynon D100.
Empannage Fitting
Pushed on with building the instrument panel. Fitted the Dynon D100, GPS mount, ICOM Radio, Garmin Transponder and AF-2500 Engine Monitor.
Test Flight with Bob Cole at the controls
I decided to take a break from the empannage. As it's cold outside - so I decided to plan the instrument panel layout and make a (second) mockup in MDF. Sunday. I am pleased with the layout so decide to cut the instrument panel.
Empannage Fitting
Continuing work on the empannage. Fitted nutplates to fuse. Re-fitted rudder to check alignment of lower end cap.
Test Flight with Bob Cole at the controls
Spent most of this evening fitting nutplates!
Empannage Fitting
Friday evening, completed rudder leading edge. Saturday, fitted the rudder for the first time. Sunday, I have managed to fit nearly all the fiberglass finishers to the empannage (Rudder, HS & Elevators). They need some filler to finish but its been a good days work.
Test Flight with Bob Cole at the controls
Just a couple of hours in the workshop this evening. I finished forming the curve on the rudder leading edge. Then primed ready to rivet tomorrow evening.
Empannage Fitting
This evening I started to roll the leading edge of the rudder. It's bnot easy and I need some help, so I decided to play with my intrument panel mock up instead.
Test Flight with Bob Cole at the controls
A BIG day today. I ordered the engine for the project and placed my deposit. I could have it within two weeks but they will hold on to it until I am ready for it. This evening I continued work on HS fairing.
Empannage Fitting
Back on the project after a break. I now have the #6 screw countersink nut plates, so I fitted them for the inspection covers. Continued work on the HS fairing.
 
I have been away from the project for a while, and collected some parts for the RV wile visiting Florida. John has helped and collected my parcels ready for my arrival. I even managed to collect the new Dynon D100 Electronic Flight Information System.
Empannage Fitting
Worked on the finish strip under the HS.
Test Flight with Bob Cole at the controls
This evening I drilled the elevator horns, fitted trim servo and control rod.
Empannage Fitting
Riveted the trailing edge of the rudder. I had put this off for sometime as it seemed very hard to get right - I needn't have worried. It went well. I then fitted the left elevator and had a heart stopping moment when I thought I had something really wrong.
Empannage Fitting
Started to fit the empanage, so I can fit the elevators and rudder.
Empannage Fitting
Just a few hours in the workshop, fitted rudder cables and steat belt cables (as I was already inside the fuse!).
Test Flight with Bob Cole at the controls
Today I decided to fit the firewall bulge. Also bonded rudder trailing edge
Empannage Fitting
Worked on firewall this evening.
Empannage Fitting
Finally finished painting the cockpit floor, stripped all the masking off this evening. Removed the masking from the firewall and front of spar. Looks nice now! Now reinstalling parts, started with rudder pedals and brakes, then fitted the flap control bar. I won't be fitting the instrument sub panels yet as I need to do some riveting on the firewall and the fuse side skins.
6th September 2005
Repainted the cockpit footwell AGAIN. Yes, I was not happy with the results last night so I have rubbed it all down this evening and re-painted it again. So far it looks good, tomorrow morning will tell.
5th September 2005
Repainted the cockpit footwell this evening.
Empannage Fitting
My brother Andy (and his wife) visited this weekend. So he came and helped out with the engine frame fitting. I had thought it was going to be harder and heavier. Hence asking him to help, but it went on quickly and easily.
Empannage Fitting
Prep'ed and sprayed the cockpit footwell area, it didn't go very well I used a different brand of cloth with the panel wipe and it left microscopic fibres behind. So after sprying it looked like I had been through a sand storm!
1/2nd September 2005
Worked on instrument panel design, I got some MDF to mock up the panel. I don't have the Dynon D100 yet so I don't want to cut the original panel.
Bob & I taxi for runway 25 at Thruxton
Bob & I strap in for the second flight
Second take off, quick & rapid climb
 
30/31st August 2005
Another big day - offered up the engine to the frame to see were the controls may need to come through the firewall. All seems well so I have decided to put the fuse on it's wheels.
29th August 2005
Really big day engine arrived - Jade Air delivered my Superior IO-360 engine this morning.
Test Flight with Bob Cole at the controls
Refitted canopy this evening to check the space behind the instrument panel. Jo came and helped fit the canopy then we played flying........
Empannage Fitting
After a really bad week I am finally able to get back to my RV project. Building aeroplanes is far more fun than fixing house plumbing problems, especially when it involves the heating and it's in minus figures outside! I have finally planned what circuits to have on the RV, so I decided to continue the panel work by drilling the switches and circuit breaker holes. I also completed the map box. Fitted the throttle, prop and mixture controls. The shorter lead arrived from Advanced for the AF2500 engine monitor. Weather still bad, so it's just a few hours at a time in the workshop!
Checked all brake pedal lines. Planned Instrument circuit braker layout. Didn't do much more it's 27F outside tonight - workshop is not much above that!!
Empannage Fitting
Today I decided to complete my parking brake. I have already made the bracket but needed some brake line parts to continue - so it was shelved for a while. The parts arrived with the firewall forward kit. As it's being mounted on the firewall and the brake lines come through the firewall I figured it was as good a time as any to finish the job. Even though I say so myself I am pleased with what I have done.
Test Flight with Bob Cole at the controls
Started work on the firewall. Fitted batterybox, master and starter relay's. Fitted various nutplates on firewall.
Empannage Fitting
The right wing is now complete. Again Jo came out and helped me pack it away into the roof of the workshop. Started on the firewall forward - battery box. It's really cold this evening so just an hour in the workshop.
Test Flight with Bob Cole at the controls
My firewall forward kit arrived from Vans. It's like Christmas has come early!! Jo came out to the workshop this evening and help move the wings around. I just have a few small jobs to complete on the right wing.
Decide to wait for the firewall forward kit to arrive from Vans before continuing with the fuse work. I had been given a Duck Works landing light by another builder and finally decided I would fit it.
Fitted left hub and wheel. It's really cold in the workshop this evening, so I didn't do much more. Ordered the firewall forward kit from Vans this evening.
Empannage Fitting
Decided to fit the landing gear on the engine frame today. Quite a big milestone the wheels going on for the first time.
Test Flight with Bob Cole at the controls
It's the week leading up to Christmas, so my time is taken up shopping and Christmas parties. It the moment I am held up waiting for very small odd parts to arrive. When they do I then seem to find I am missing another small part - stopping me from continuing! However I have pushed on with painting the instrument sub panel as I want to rivet it in place and start fitting wiring.
Fitted brake pedal hydraulic lines.
Test Flight with Bob Cole at the controls
The fuel tap arrived from Andair this week so I have gone back to building the fuel pump assembly. This needs to have 5" of straight pipe in and out, so it's been a challenge to find a suitable location.
Empannage Fitting
Fitted brake pedal hydraulic lines.
 
Test Flight with Bob Cole at the controls
Fitting the rear skin and rollbar. John (W) comes and helps out.
Empannage Fitting
The rear skin has to be riveted in place before the angles (on seat brace X section) can be riveted in place, otherwise you can get to the skin rivets.
Test Flight with Bob Cole at the controls
Topcoat time. I wanted toput the top coat on final skin before fitting. Hopefully to make it easier.... but I still managed to get a few runs!
Empannage Fitting
The mission today to prep and prime. This is where it started to go wrong.... as I manage to dent the canopy skin. It's a write off.
Primer time - I have dismantled the rollbar, canopy and the rear fuse ready for painting.
21st July 2005
Starting to think about the avionics. The panel layout and area behind needs to be planned.
Test Flight with Bob Cole at the controls
Started fitting the canopy rear catches..
18/19th July 2005
Dimpling the final rear skin, and prep ready to start spraying..
The rudder has some blind rivets that stand proud from the skin. It's bugged me for a while, so this morning I decided I could not look at them any longer.
Empannage Fitting
A few hours over the past few days, continued working on canopy. Fitted struts.
Finished cutting the rear window, made final trim. Started on canopy side strips.
Empannage Fitting
Continued work on rear window, drilled all fixing holes.
Test Flight with Bob Cole at the controls
Started fitting rear window.
Empannage Fitting
DID IT - cut the canopy. I had to do it sometime and as it was warm and sunny today I went for it. Heaters on, marked it out and started cutting..
Test Flight with Bob Cole at the controls
Finished riveting the canopy frame together, ready for the perspex now.
Empannage Fitting
Still working on the canopy re-enforcement.
Test Flight with Bob Cole at the controls
7th July 2005
Continued with re-enforcement.
Empannage Fitting
Started work on the canopy re-enforcement option.
Test Flight with Bob Cole at the controls
All holes drilled for canopy frame.
Empannage Fitting
Worked on trim servo mounting - fuse.
Test Flight with Bob Cole at the controls
Started on the canopy strut brackets.
 
Empannage Fitting
Worked on canopy latch & tidied workshop this evening.
Test Flight with Bob Cole at the controls
Continued work on the canopy - Fitted canopy side rails.
Empannage Fitting
Continued work on the canopy frame.
Test Flight with Bob Cole at the controls
Fully drilled the front pivot's for the canopy tonight. Had to also adjust the top panel so it didn't catch the front edge of the canopy skin..
Empannage Fitting
Continued work on canopy frame. Fitted the first rivets, the canopy is coming together.
Test Flight with Bob Cole at the controls
Made canopy release catch. Started fitting the canopy frame.
Empannage Fitting
15th June 2005
Cut the canopy release hole in the side of the fuse..
Went flying today and collected some extra nut plates from Robert, all fitted by late afternoon.
Empannage Fitting
Back from Colmar - straight into the workshop!!!
Test Flight with Bob Cole at the controls
Riveting and dimpling rear skin and brace. Also thinking about where to fit the strobe power pack, under baggage floor or behind seat?
Empannage Fitting
Riveting in the center (seat brace) bar, also finished the last recline position.
Test Flight with Bob Cole at the controls
Worked on trim servo mounting - fuse.
Empannage Fitting
Just an hour working on the RV this evening. Fitting pedals.
 
Test Flight with Bob Cole at the controls
Brake pedals and fuel vent line.
Empannage Fitting
Fitting tail wheel spring bracket and final bulkhead.
Test Flight with Bob Cole at the controls
Mostly preparation and painting.
Empannage Fitting
Just a few hours in the workshop this evening, finished assembly of the rolloverbar. I want to get some more parts complete for another batch of spraying.
Continued work on fitting HS and VS, trail wheel mount is ready to prime and fit. Prep work for more priming. Jo came and took some pictures of me working on the VS.
A good day in the workshop today, continued with fitting of the empannage.
Test Flight with Bob Cole at the controls
Started fitting the HS tonight, Jo came out and helped with the measurement.
Some work on the canopy mounts. Started making brackets to fit empannage. Collected top coat paint for cockpit area.
Empannage Fitting
Another evening in the workshop, reviewed my painting from lastnight. Still waiting for my flaring tool to arrive from the US so decided to fit the nutplates to the center floor vents and fuel pump mount.
Spraying front half of cockpit interior. Updated the Painting Page, bigger pictures and added details about paint being used.
15th May 2005
Popham RV Fly-in. Got back and tidied workshop.
Empannage Fitting
Left wing, tank bracket and finishing strip.
Right fuel tank bracket, and fuel tank breather.
Empannage Fitting
Right flap control rod.
Fitted right flap to wing.
Empannage Fitting
A really big milestone this evening. John (RV6 builder) came over and helped with the wing alignment.
Test Flight with Bob Cole at the controls
Jo helps with the trial wing fitting. The first wing is mated to the fuse. Tomorrow John has offered to come over and help with the alignment.
Empannage Fitting
Started work on front section of canopy - the hinge to front fuse.
A little work on the canopy release mech..
Empannage Fitting
More work on fuselage, canopy rollbar to rear fuselage brace (the modified version from Vans). Flap control rods.
Test Flight with Bob Cole at the controls
Tony & I fitted the final wing skin today, completed in approx 2hrs.
 
Empannage Fitting
Started fitting the final wing skin.
Fitting Fuel pump and filter housing in fuse.
Empannage Fitting
Fitting rollover bar to fuselage.
Test Flight with Bob Cole at the controls
Building brackets to fix rollover bar to fuselage.
Empannage Fitting
Painting tonight, and riveting rollbar together.
Test Flight with Bob Cole at the controls
Rest of the parts arrived - damaged. Start work on rollbar with replacement parts.
Part of my order arrives from Vans.
18th April 2005
Continued work on flap.
Empannage Fitting
Fitted aileron and started fitting flap.
Test Flight with Bob Cole at the controls
Continued with wing, aileron brace and drilled pitot today.
14-15th April 2005
Aileron hinges complete and riveted on wing.
Test Flight with Bob Cole at the controls
Wing, aileron hinge.
Empannage Fitting
Started work on left wing, match drilled aileron hinges and wing skin.
10th April 2005
Jo helped me get the left wing down (stored in roof of workshop) to start work on it.
9th April 2005
Cleaned and tidied workshop.
Test Flight with Bob Cole at the controls
Fitting canopy latch.
Empannage Fitting
Fitting building the canopy hinges.
Test Flight with Bob Cole at the controls
We have finished the wing. Jo has written about working on the RV.
Jo helps with a few more rivets on the wing.
Jo is fantastic. She arrived in the garage today, and asked if I wanted help fitting the wing skin. Jo has never riveted so I gave her a quick lesson and then we started on the wing skin. Jo did a great job taking lots of care to ensure the job was done properly. The skin looks great. Thanks Jo.
Empannage Fitting
Today I finished one elevator, I had left finishing the skin so the rivets could be inspected.
 
Riveted baggage floor. Also managed to fit a few wing rivets. Will hopfully have some assistance at the weekend.
Test Flight with Bob Cole at the controls
Sprayed parts, a few more rivets in the wing skin and started fitting the fuse baggage floor.
Empannage Fitting
Started riveting the last wing skin on, it's not going to be possible to do it on my own.
Test Flight with Bob Cole at the controls
I find a problem with the rollbar I have been working on.
Painting.
26th March 2005
Deburring rollbar.
Empannage Fitting
Fitting top skins to rear and front deck.
Test Flight with Bob Cole at the controls
Working on the rollbar.
Empannage Fitting
Building the rollbar.
Starting the canopy rollover bar, making the brackets.
20th March 2005
Seat back brace. Canopy latch work on fuse.
Test Flight with Bob Cole at the controls
Fitting angle round top of instrument panel.
Empannage Fitting
Cockpit, forward fuselage.
Test Flight with Bob Cole at the controls
Some odd jobs....
Control rods.
Test Flight with Bob Cole at the controls
Interior.
Empannage Fitting
Fitting flap motor.
Aileron rods & rod ends.
Fuse interior.
Pedal fitting.
Empannage Fitting
First fitting of the centre cabin cover and fuel tap housing.
Test Flight with Bob Cole at the controls
Flap motor assembly, and luggage floor.
Empannage Fitting
Building flap motor assembly, Aleix is helping.
Test Flight with Bob Cole at the controls
Aleix came over and helped shoot the last rivets in the seat backs and tunnel cover.
Empannage Fitting
Really great progress this evening. Riveted the seat backs, brake pedals, seat braces, tunnel cover and elevator bell crank. Very pleased with progress tonight.
Spent the evening painting (primer), wing panel, and seats.
 
Empannage Fitting
28th February 2005
Made tunnel cover, prepared parts ready for spraying (Snowing outside workshop this evening!).
Built seat brace, dismantled and de-burred seats ready for primer. Dismantled brake pedals for priming.
Empannage Fitting
Building the seats.
I have decided to make the parts for the seats while I am wait for my right wing to be inspected.
23rd February 2005
Deburred rudder pedals... .
Deburred rudder pedals, and reviewed parts for rudder assembly.
21st February 2005
Started drilling tail wheel bracket - WD-409. Too cold in the workshop came in after 45mins (it's been snowing today).
Waiting for inspector to visit, so started on fuse - tail wheel.
Empannage Fitting
Finished dimpling right wing skin, fitted inspection cover.
Started work on right wing skin.
Aileron control rod.
15th February 2005
Worked on aileron control road, fitting the 4-12 rivets was difficult.
Empannage Fitting
Riveted flap hinge to wing.
Empannage Fitting
Finished fitting the rivets to aileron gap fairing (W-724) that had caused so many problems yesturday. Made spacers for aileron hindge. Made aileron push rod (too short, will have to re-order). Painted aileron push rods. Also visted Machine Mart for some more tools - which were nearly all out of stock.
11th February 2005
Started to fit rivets to aileron gap fairing (W-724) .... they were not very good so I removed them and decided to call it a night!!
Test Flight with Bob Cole at the controls
Fitted brackets to aileron, and trial fitted aileron to wing.
Empannage Fitting
Started riveting outer aileron hinge bracket to wing.
Test Flight with Bob Cole at the controls
Painted aileron hinge bracket abd W-721, started riveting aileron hinge bracket together.
Trial fitted W-721.
Constructed the aileron hinge bracket assembly.
 
Empannage Fitting
Started work on the right QB wing.
Built jig for QB wings, put right wing in jig.
Empannage Fitting
Completed right elevator. Rolled elevator leading edges. Completed HS.
Test Flight with Bob Cole at the controls
Started assembly of right elevator.
Empannage Fitting
A full day (approx 7hrs) working on the RV today. Finished the left elevator & trim tab.
Test Flight with Bob Cole at the controls
This week I have been back working on the bathroom refit, so it's only weekend RV work. Saturday today did 3hrs finishing off the elevator ribs. Replaced a few rivets not up to scratch and started to fit rear spar.
A really good full day in the workshop, I completed the left HS stabilizer skin and cleco in the rear spar into place. Then back riveted both the elevators ribs in.
2nd January 2005
Went flying in my Cessna 150 EV to North Weald.
Empannage Fitting
This morning I managed a couple of hours in the workshop to finish riveting the top left front rib HS skin. Jo came out and took some pictures for me - before the camera batteries went flat. Also had a few hours this afternoon..!! (5hrs).
 

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