Scott & Tanya Card RV9A build log (N4822C)

This weekend I was able to complete the installation of all of the tank attach nutplates on the main wing spars. This was a tedious process of drilling, setting up a jig, countersinking the holes, and riveting the nutplates. I drilled out the screw holes to #19 and setup an aluminum back plate with a matching #19 hole to keep a (here it comes) #19 countersink cutter centered as the hole got bigger. This worked well for me but was very slow going.

I also completed fitting of the tie-down / aileron horn brackets. I mis-drilled one of them because I aligned it upside down when match drilling the holes for the aileron horn. So that one has an extra set of holes in it. It will be fine, but I might redo it if I feel the need. I’ll think about it.

 

  

  

  

 

This evening I completed inventory of all wing parts hardware bags. Everything is accounted for except for one small hardware bag that was back-ordered (I expected this). Tanya and I carefully moved the wing skins and other stuff into the spare bedroom that we are using for parts storage. I fully expect to resume building after parts organization this weekend. The pictures show the state of things after everything was put away, the crates broken down, and spars up on the wing stand (upside down for the first operation). Many thanks to Tanya for sorting all of the hardware bags into proper storage. It took her almost three hours. You may notice that in addition to clamping the spars to the stand, I also drilled holes in the aluminum angle that they are sitting on and dropped a pin (actually a screwdriver) through each end to be absolutely sure they couldn’t just slip off of the stand. That wouldn’t be good at all for one of the spars to come crashing down. Still no actual build time, just setup.

 

  

  

  

  

  

  

 

The wing kit was delivered today. What an exciting event. The crates were in very good shape (no damage) and all of the contents were packed very carefully as always with Vans. I spent about 4.5 hours diving in and taking inventory. It will probably take me another day or so to get everything inventoried and put away. The quantity of packing paper always amazes me. I can’t wait to dive in and start drilling on that big beautiful wing spar :).

 

  

  

  

  

  

  

 

I’ve been using the Roadway Express website to track the progress of shipping of my wing kit since I got the letter from Vans saying they had been shipped. Today I noticed that they arrived in the local Austin terminal. I decided that I would call them instead of waiting for them to call me to schedule delivery. I’ve read that some builders have had their kits sitting around at the local terminal for a long time before delivery was scheduled.

They scheduled to deliver the two crates (395 lbs. total) tomorrow after 1pm. I’m going to swipe a couple of piano dollies from work to have on hand just in case they are needed to move the crates around. The excitement builds!

In the mail today I (actually Tanya) found an envelope from Vans Aircraft. The wing kit shipped via Roadway Express on 3/2/05!!! Yeah! It is currently in Dallas. I can only guess that it will be delivered this coming week. I’m very excited to get back to construction as I’ve been just passing the time for the past month. I am planning on ordering the fuselage kit well in advance so I don’t have to endure this downtime again :).

Anyway, this is great news, we’re going to be building again in the next few days!