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Dave's RV-7A Builder's Log
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Date:  1-22-2017
Number of Hours:  6.00
Manual Reference:  
Brief Description:  Exhaust hangers and throttle sub panel

Today was sort of a two steps back day…I ended up remaking my throttle sub panel and working on exhaust hangers during the time between paint coats. Although these days can be a bit frustrating, in the end I’m always happier with the finished product. The exhaust hanger exercise was a lot of work—mainly due to the poor access behind the engine—but in the end I got the verticals done. Still need a solution for the horizontal hangers, but I have a few ideas that I’ll try. The throttle quadrant sub panel was another matter.

It all started yesterday when I was wrapping up the exhaust hanger work. Shortly before I left for the day I had sprayed some clear coat on the throttle sub panel in preparation for adding the dry transfer decals and reinstalling in the aircraft. When I got to the hangar today the clear coat had dried with a “crackle” finish—a total fail, but at least I hadn’t tried to shoot the whole panel with it. The throttle sub panel was the original part sent from Van’s and in my opinion, wasn’t really as robust as the rest of the panel since it was made from significantly thinner aluminum stock. Add to that the fact that I had made the throttle cable hole ¾” (like the prop and mixture cables) when it should have been ½”, and I started thinking about making a new one. I found a piece of the original panel (.063 I think) that was barely big enough to remake the part…but I would have only one shot if I messed it up.

I cut it to shape on the bandsaw, worked the edges to get nice straight lines, and then put it in a makeshift bending brake in the vice. Trying to bend it by hand was pointless, so I got out the deadblow hammer and went to work. The pictures show the results—it came out really nice. After sanding and cleaning the part, I shot it with primer, paint & clear coat, and when I was finished I had the piece I originally envisioned. Now I can apply the decals and move on to the whole panel.
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New sub panel in the

New sub panel in the "bending brake"

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After some persuading with the dead blow hammer

After some persuading with the dead blow hammer

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Shaped, drilled, sanded and cleaned

Shaped, drilled, sanded and cleaned

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