Scott & Tanya Card RV9A build log (N4822C)

Tanya and I continued shooting rivets on the bottom wing skins. We finished the left wing. It is all closed up, and we did finally get the quick efficient process worked out. Poor Tanya is being forced to work quickly and accurately because the bucker quickly gets tired holding the bucking bar up over the head at full arm extension and applying pressure to the tail of the rivet. “When I say shoot, you better be ready to pull the trigger.” :). Yep, we’re still married, and got it all figured out . We got one wing done and moved on to the other. The rear spar and about six rivets down all of the ribs are done on the right wing. The repetition and smoothness of rhythm is the key to shooting all of these rivets blind. Another rivet session or two and we’ll have the right wing closed up.
The sequence worked out great: Shoot all of the rear spar rivets, then about three rivets forward on all of the ribs, repeating a few rivets across the whole length of the wing a few times until it isn’t reasonable to peel the skin back to stick your arm in there (about 12 remaining on each rib?). Then cleco the rest of the forward edge down and reach in from the access holes and ends to close it all up. This works on the RV9 wing, but might not work on the wider RV7 wing. I’m guessing that on the RV7, you wouldn’t be able to reach the rear spar from the forward edge unless you had a super long arm. Oh, well, that is somebody else’s problem.
I also got the outside air temperature probe installed with a snap bushing in the bottom of the right wing skin. A little touch of proseal on the inside and it will be golden.

 

  

  

  

 

Started riveting the left wing bottom skin on. Ugh. We’re doing the riveting with the wings in the cart. I’m doing the length of the rear spar first, then moving down and out from there. I’m using Steinair 1″ square tungsten bucking bar. It is working pretty good so far. We’re just trying to get in the groove of me reaching all the way up in the wing and bucking all of these rivets blind. It was slow going this evening, but I’m sure we’ll pick up the pace.

 

  

 

I got the AOA ports installed in the outboard bay of the right wing. I found that the #4 screws sit nice in a #30 dimple so that is what I did. I also installed a grounding location on the spar on the inboard end. The landing light bulbs have been installed.

 

  

  

  

  

  

 

I’ve been very slowly getting back into finishing up the wings. I’ve been spending more time looking at them than doing much actual work. I’m stringing some wires and such right now. Not too exciting. I verified that the outside air temperature sensor works and got its wires run. I remade one of the aileron stop brackets that I wasn’t totally happy with. I also need to start looking at the installation of the AOA ports in the right wing.

I spent a few hours doing all kinds of little things on the fuselage. I installed the seat belts and some sound proofing material on the firewall. I pulled out the autopilot head to send to TruTrak for the latest software update just for good measure. I also removed both P-mags to send to Emagair for software updates as well.
As far as I can tell, the fuselage is all done. Let me know if you see something I’ve missed. So, it is now time to finish up the wings. They have been living in our living room inside for the last year and a half. They are all complete except for a few wiring details, wing tips, autopilot servo install and riveting of the bottom skins (skins are fully drilled, deburred, dimpled, and ready for riveting). We moved the fuselage over a little more in the garage and moved the wings out. In order to make enough space, we moved a work bench and engine hoist into the house where the wings were (Tanya’s idea) for storage.