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Dave's RV-7A Builder's Log
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Date: 4-19-2007
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Number of Hours: 8.00
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Manual Reference:
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Brief Description: Aileron construction
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I intended to start working today by priming the aileron ribs and counterweights--hoping to get going before the wind picked up...no such luck. Even with the wind, the priming went well and I was quickly working on assembling the right aileron. I have proven over and over again that reading and following the plans is the best way to ensure success in a project like this...today I got a little ahead of myself and began riveting the skin on before I had riveted the nose ribs to the spar--paid for that mistake a little later in the day.
The process of riveting the upper skins to the spar is a bit difficult to say the least. I decided to turn the aileron over and use tape to hold the rivets in place while I shot and bucked them. Unfortunately, the access to the spar is limited and you pretty much have to buck by feel as there is no way to watch the gun and the bucking bar at the same time. It worked, but it wasn't a lot of fun. Following that, I inserted the main ribs and (as per the plans) only riveted the top sides. It was then I noticed that I hadn't riveted the spar to the nose ribs yet. Fortunately, I had not riveted the bottom skin on, so it was a simple (sort of) matter of shooting the six AN426 4-5 rivets with an offset rivet set. It worked.
Finally, I turned the whole thing over and finished squeezing the main ribs and nose ribs, before I clamped the aileron to the table for the final riveting with blind rivets. All went well and I was done except for four rivets that I couldn't squeeze at the aft end of the main ribs. It was the same sort of problem I ran into on several of the empennage surfaces. Out comes the no-hole yoke, and after about 20 minutes of adjusting and tweaking, I realized it wouldn't work...but as I was turning the aileron for better access, I dropped it. On the floor. The dent isn't fatal, there was no structural damage, and the location will be concealed by the gap seal, but the lesson learned is "don't get too clever and forget the basics".
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Aileron clamped to table for riveting upper spar
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Riveting lower spar with blind rivets
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Aileron temporarily installed on right wing
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