Scott & Tanya Card RV9A build log (N4822C)

I dare to say that the empennage is nearly done. I have spent the last two days polishing off little tinkering tasks such as trimming elevator counter-weights and trimming the length of the trim tab pushrod. We did a trial fit of the elevators on the horizontal stabilizer. It looks really good. The elevators and stabilizer are very straight and true (no detectable warp). Tanya and I spent a few moments talking about the failure mode of the elevator counterweights coming loose. That would not be good at all and would cause catastrophic control surface lockup. I’ll probably take some “extra” precautions when finally securing the counterweights.

A couple of tips for the first time you hinge the elevators to the stabilizer: Use bent 16d nails as temporary hinge pins and use the wedges created from the trim tab jig to slightly pry the elevator hinges apart when fitting the elevator. These two things make fitting much easier.

Yesterday I completed the rudder leading edge bend. I thought I had a good plan of attack, but it ended up being just an exercise in persistence. I still don’t think I got enough bend in the second edge as there was still a little (relative term) tension in it when I set the rivets. It will be fine, it was just a pain in the rear and I didn’t gain any wisdom to pass on.

Tomorrow I’ll do a trial fit of the rudder on the vertical stabilizer. I expect this to be pretty uneventful. The only thing left to do (other than fiberglass tips) is to drill the elevator control horns to the center hinge bearing. I imagine that I’ll start trimming the fiberglass parts after that as my wing kit isn’t scheduled to arrive until about the beginning of March. Bummer. I guess I’ll have to use the next month to catch up on the rest of my life :). IE. house repairs, boat prep for the up-coming summer, etc.

 

  

  

  

  

  

  

 

We completed the horizontal stabilizer. Tanya held the bucking bar for most of the skins and I ran the gun. It worked out quite well. I did put one small dent in the top skin because I didn’t have the flush rivet set perfectly square. Oh, well. I’m sure I’ll just have to live with a few such mistakes. The completion picture is after it had already been carried into the spare bedroom where we’re keeping airplane parts.
After the stabilizer was complete, I got out all of the rudder parts that had already been prepared and primed. So, I started assembly of the rudder. I’ll wait to do the rudder trailing edge until I am ready to do the elevator trailing edges.

 

  

Completed Horizontal Stabilizer

  

Parts shelves inside

 

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.

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.