Scott & Tanya Card RV9A build log (N4822C)

I got the fuselage up on the gear legs today. I’m leaving the wheels for later so it is lower and more stable. Many thanks to Jeff B. for the engine hoist and eye bolt setup that we used to very easily lift the airframe. This was a completely no stress operation. Tanya and I repositioned the fuselage a bit in order to make plenty of room for mounting the engine and doing cowling work. There is nothing like the reconfiguration of the shop to indicate progress.

 

  

  

  

  

 

I’m beginning to work on the back of the engine to try to be sure that I have as much “stuff” (fittings and accessories) on there as possible before mounting. I installed the tach output dust cap (since I won’t be using a mechanical tachometer). The oil temperature sensor goes in the hole just below the oil filter. I’m doing a rush order with ACS to get some steel fittings for the oil cooler input and output.

 

  

  

 

We finished riveting the aft top skins. Not so much fun crawling back in the tail cone to shoot all those rivets. After the riveting was done I installed the seat belt anchors and did a little anti-chaff protection of the static tubing back there. I used blind rivets for the last three rivets on either side of the forward skin. There is a large bracket behind those locations that make it impossible to shoot a solid rivet. I had long ago planned for this and ground a small recess in those rivet locations into that bracket in order to be able to even get the blind rivets in there. It worked out fine. The canopy frame went on for the last time and we riveted on the upper brace. I had previously made a cover for that brace with some lights in it. I’m quite happy with how it turned out. Lastly I put on the ELT antenna and made a little clip to hold the antenna. I used a blind rivet to secure the clip with a small plastic washer between the clip and the frame.

 

  

  

  

  

  

  

  

  

  

  

  

 

The seats that I ordered from Classic Aero arrived. They look pretty nice. I sure wish they were lighter. The seat backs with internal frames weigh 8lbs. each, the bottom cushion is another 3lbs., plus probably another 1.5lbs. (I didn’t weigh them) for the foam under the seat bottom. So, total, about 12.5lbs. per seat. Oh well, the cost of being very comfortable :). I’m very happy with the quality of the upholstery work and after about 15 minutes of seat time with airplane noises, I think they are going to be very comfortable. They have a very nice little pocket on the seat backs and adjustable lumbar support. I got mine without headrests. The seat backs come with the lower attach hinge left for the builder to customize the side to side placement. I found this process to just be trial and error. I’m pretty sure that I’m just going to leave off the upper support bracket at least on the pilot’s side and let the seat back just rest on the rear bulkhead.

 

  

  

  

  

  

  

 

This is mostly just a status report with pictures. The panel is back in. I used some stainless steel black oxide button head hex screws on the panel with some small plastic washers under them (from McMaster carr). I labeled all of the fuse positions. I soldered the wires on annunciator lamps and momentary switches for the AOA. I used some 1/2″ black silicone self fusing tape from McMaster to wrap those connections. I’m very happy with how that worked out. The pitot and static tubing is all connected behind the panel. Manifold pressure tubing to the sensor is installed. I also got the cabin heat control cable installed. I finalized all of the control stick nuts and bolts and installed the push tube from the controls to the elevator bellcrank. The fuel selector valve is now installed as well.

Now we’re riveting the rear top skins on the fuselage. I spent a couple of hours inside the aft fuselage last night on a board with Tanya inserting the rivets from the outside. Another couple of sessions and the aft riveting will be done. I’m starting to think about landing gear and wheels now.