Scott & Tanya Card RV9A build log (N4822C)

This week I made some serious progress on the elevators. I’m doing them both at the same time. The first pre-assembly was done and holes drilled. Nothing too exciting to report, except it still surprises me how much time simple things take during the pre-assembly phase.

I fabricated (twice) the little gusset that firms up the trim tab spar and root rib on the left elevator. My first attempt turned out exactly as shown on the plans, but still didn’t leave sufficient hole-edge clearance for my comfort. I believe this was mostly due to bend radius of the completed part. So, I made another one that was a little longer. I am much happier with it.

 

  

workin' on a part

  

  

left elevator

  

right elevator

 

Tonight I went to visit David Nelson who is building an RV7. His plane is very similar to the one I’m building except with slightly shorter wings. I found him by looking through the roster of our local EAA chapter. To my surprise, he lives in my same neighborhood! He is currently building his wings and is about a year into his project. We spent the better part of 3.5 hours talking about construction details and experience. It was a fantastic learning experience for me. Thanks David for all the great information. I have adjusted some of my basic procedures based on his experience and demonstration. (Squeeze the dimples harder. Less part warping and a better, deeper dimple.) Below are some pictures of his project.

 

  

  

 

I already had all of the rudder parts prepared, so it was just a matter of final riveting to complete the rudder except for the trailing and leading edges. Using a longeron and 4″ yoke, I was able to squeeze all of the rivets. I used the longeron yoke to squeeze the difficult ones inside the base reinforcement bracket. The only blind rivets that I used were for the last (aft) rivet in the ribs.

When fitting the skins, I had to do some trimming of the forward edge of the stiffeners in the middle where they came too close to the spar doubler plate. I’ll set the rudder aside for trailing edge completion when I have the elevators ready. This concludes all of the “pile of parts” that I had prepared and primed. So, on to the elevators…

 

  

rudder counterbalance weight installed

  

trimmed rudder stiffener

  

  

  

Rudder control horn

  

  

no (optional) blind rivets needed here

  

blind rivet in last hole

  

 

I left off with parts prep at the elevator counterbalance ribs just before I setup to do a bunch of priming. So that is where I pickup again. I got the elevator parts back out and re-checked hole alignment in the counterbalance ribs and did some hole dimpling in the ribs.

 

  

 

We completed the horizontal stabilizer. Tanya held the bucking bar for most of the skins and I ran the gun. It worked out quite well. I did put one small dent in the top skin because I didn’t have the flush rivet set perfectly square. Oh, well. I’m sure I’ll just have to live with a few such mistakes. The completion picture is after it had already been carried into the spare bedroom where we’re keeping airplane parts.
After the stabilizer was complete, I got out all of the rudder parts that had already been prepared and primed. So, I started assembly of the rudder. I’ll wait to do the rudder trailing edge until I am ready to do the elevator trailing edges.

 

  

Completed Horizontal Stabilizer

  

Parts shelves inside