Scott & Tanya Card RV9A build log (N4822C)

It was a productive building weekend. I started with some component re-tasking since my Subaru engine plan fell through. I had previously cut the heater box off of the center tunnel cover for the heater fan unit that comes with the subaru package. Well, I decided to just put it back together with a little reinforcement strip. I felt kind of silly with how long it took me to bend all of the little vent louvers. I had previously thought I would use an Andair fuel valve but after seeing the cost, I think the vans valve will be just fine :).

It is high time to be figuring out interior paint. We decided to use a standard Rustoleum “Smoke Gray” from Home Depot aircraft supply. I wonder how many cans it takes to paint the inside of an RV. I bought 15 cans. I bet I have enough to do two airplanes. I also did a test patch on some primed aluminum. Looks great.

I have spent some time recently doing some firewall penetrations for control cables. Drilling a small rivet hole in the stainless firewall is one thing, but cutting a larger hole is a serious pain. I decided to splurge (imagine that) and buy a 2″ knockout punch for the heater hole. It worked like a charm. Now if I could rent out the tool over the rest of my life, I might be able to recover the cost (it was expensive).

Now on to the fun stuff. I cleaned up and reset the garage and Tanya and I hauled out the horizontal stabilizer and elevators. I put both elevators on the stabilizer and set the whole thing upside down on the bench. I marked the first pushrod attach hole and drilled. Then I prepared an aluminum block as a drill guide and drilled the second one. Piece of cake, but very nerve wracking. I still haven’t bolted up the pushrod yet, so I don’t have the final verdict on how I did.

With the elevator horns drilled, I moved on to aligning the stabilizer on the fuselage and drilling the attach bolt holes. I used a standard steel measuring tape for alignment measurements. I did all of the setup with all of the shims in place under the mounting brackets. This is different than the instructions say, but it made a lot more sense to do it this way. I clamped the whole assembly in place and re-measured everything. Then I re-measured again, went and ate dinner, had a coke, looked at it, measured again, then did the layout for the bolt holes. After a little more checking my measurements, I drilled the attach holes. I think it took me the better part of two or three hours to drill these eight holes. For those not paying attention, these few holes directly affect how this thing is going to fly.

Whew… The horizontal stabilizer is mounted. What is next? I think it is time to make some kind of provision to get the elevator trim wiring to the trim servo (a hole and a snap bushing). Then on to the vertical stabilizer! Yippee. Great fun. Did I mention that we’re super excited to have a hangar?

 

  

  

  

  

  

  

  

  

  

  

  

  

  

  

  

  

  

  

  

  

  

  

  

  

  

 

I have placed an order with Mattituck for an O-320-D1A roller tappet Lycoming (clone) engine. It will be setup for a constant speed prop with ECI cylinders, dual P-mags, and all the trimmings. Lead time is supposed to be about four months. Maybe this one will work out :).

Tanya and I are very disappointed with our business dealings with Eggenfellner Aircraft (EAAINC). We got the run around and seemingly blatant lies about the status of our order for many months from Jan Eggenfellner and his staff. He requested and received full payment for our order when there is no way he could have expected to ship it on time. In a telephone conversation that I had with Jan on 1/18/06 he said that the package that he sold me was not as complete as he thought it was and that he just got the engine mount back from powder coating in November. Note that this is after he had been holding full payment for six months and been less than forth coming about the order status. Jan stated that he understood that he was treating my order unfairly, but that he was making a business decision to delay my order so he could work on H-6 package orders. He even commented that a number of those engine packages hadn’t been paid for yet. I just couldn’t believe what I was hearing. He gave additional assurances and promises of delivery. After more than eight months of EAAINC holding full payment and clearly demonstrating a lack of interest in delivering our order, I requested a full refund. Our payment was promptly returned with a note stating “We are sorry we were unable to deliver your order as promised.”

The factual history of our dealings follow:
(more…)

This morning we closed on the purchase of a hangar at Georgetown Municipal Airport (GTU). Tanya and I are quite relieved that we have a home for our project when it comes time. My guess is that we are at least eight months away from actually needing the space. Until then, we are renting back to the previous owner month-to-month while he sells the Piper Vagabond that he has.

 

  

  

  

  

  

  

  

 

The forward top skin custom access panels are finally done. Ok, I’ve been slacking. I decided not to put any RTV in between the backing ring and the skin. If those rivets holding it on leak a little rain water, what is the difference from all the other rivets? I am planning on doing an in place gasket with proseal later to seal the removable panel.

I got out the ELT to check the fit in the baggage compartment after I put 1/4″ sound proofing on the bottom skin. Some of the sound proofing needed to be removed because the fit was too close. Now I’m on to other things induced from a change in engine plan. I had previously just made a flat panel in place of the firewall recess. Now I needed to get out the proper recess for drilling and deburring. I’m waiting for a very large refund check to clear before much more is said on that front…

Now I’m fabricating a fuel boost pump firewall stiffener.