Scott & Tanya Card RV9A build log (N4822C)

We began the day completing riveting the spar doublers and brackets. All spar doubler rivets were squeezed, however, it was easiest to shoot the rivets for the brackets with the rivet gun. Tanya was happy to buck them. Tip: I have found that it is most advisable to clamp any part you plan to rivet with the gun so it doesn’t move around on you. Don’t even try to shoot a rivet on a part that is going to jump around.
After the spars were done, the HS jig was setup on the bench and a skin loaded. The middle nose rib was a bit interesting to set the rivets. I think we did quite well. I can’t imagine doing the skin riveting alone.
Tip ribs were riveted in, then the spar was installed and the rest of the skin was riveted. Tanya bucked all of the rivets and I drove them. We used a bit of rivet tape on each rivet head to reduce marring. Our shop head consistency isn’t perfect, but well within tolerance. It will improve with practice.
So, we completed half of the horizontal stabilizer today. Next is to do the other half. I expect that the time to do the other side will be about half.

 

  

  

  

  

  

  

 

Started riveting together the spars for the horizontal stabilizer. I’m starting to get better with the squeezer on the large 1/8″ rivets. Tomorrow will be a full build day.

I completed final assembly/riveting of the vertical stabilizer first so that we would have something to put under the christmas tree. This is the first real riveting that I have done. I only had to drill out a total of three or four. I would call that pretty good.
I first riveted the rear spar doubler and hinge brackets together with the rear spar. Then the ribs and forward spar were assembled. The lower rib and forward spar intersection was a pain to rivet. I ended up just bending the forward bottom rib a bit so I could get to the rivet, then bent it back once it was assembled. That worked fine.
After the skeleton was assembled, I clecoed it into the skin. I loosely clamped the assembly to the bench for skin riveting. I used the thin flat bucking bar in the picture for many of the rivets where my 1lb. bar wouldn’t fit. It worked very well. I also used a little piece of rivet tape over the head on the skin to keep the marring of the skin to a minimum.

This is my first completed structure. It is very exciting to finally have a real airplane part come out of all of this. After Tanya removed the remaining blue plastic from the outside of the skin and cleaned it up with some MEK, we put it inside. I have been given a whole spare bedroom for parts storage.

 

  

  

skeleton assembly. Yes, it took all of those tools to do it.

  

  

spar doubler rivets

  

  

  

  

Finished!

  

 

We got all of the prepared parts primed today. The final finish isn’t anywhere near what I am aiming for, but it is fine for a light primer coat. I think I probably didn’t apply enough air pressure at the gun. I’ll do some tests before we take the paint booth down this week.

 

  

  

  

  

 

Ugh… That was a long day of acid etching and alodining in preparation of primer tomorrow. Maybe I should do smaller batches of parts next time. There is a picture of the “pile of parts” that I’ve been talking about (minus the skins). There were a few small glitches in preparation, but nothing major. Primer is next.

I also got the elevator counterbalance skins and ribs aligned, match drilled, and deburred today. The instructions sure are getting sparse. Much plans interpretation is required at this point. I have a lot of assembly and drilling to do for the elevators that isn’t even mentioned in the instructions. I guess this is preparation for the wing kit. Oh yeah, I ordered the wing kit yesterday! We should see the parts for the wings in two months!