Alex's Vans RV-10 Build Log

In between riveting the fuse side skins with my daughter's help, I also decided to start work on the upper forward fuselage. This begin with fabricating a number of brackets from various pieces of raw aluminum. F-1044C spacer cut to length and 1/8" hole drilled F-1044B angle cut to length with one end trimmed to match the drawing given in the plans. All that remains is for this end to be bent to the required angle Bending the F-1044B angle end in the vice. I gradually increased the bend until it exactly matched the specs in the plans. Placing the F-1044B angle over the drawing in the plans to confirm the correct angle of the bent end Remaining brackets cut to size and edges deburred F-1003C-L and R instrument panel attach flanges fluted and nutplate attach holes dimpled Next, I started preparing the F-1044A and F-1045 ribs by deburring the edges and dimpling the nutplate attach holes at the aft end and the #30 holes on the front flanges For the few holes where I could not fit ...

During downtime on riveting the fuse side skins, I made a start on step installation.  The first step involves drilling bolt holes into the Delrin support blocks. To aid in the drilling, I 3D printed a drill template.  Bolt hole drilling template At the same time, I also designed and 3D printed a drill template for a doubler on the opposite side of the baggage floor rib that I plan to install for added strength (as a few other builders have done). Doubler drilling template Bolt hole drilling template clamped to Delrin block Drilling template used to mark out doublers on Alclad sheet for cutting Hole saw used to drill out 1.5" hole in center of doublers. This diameter matches the center hole size in the Delrin blocks Using the drill press to match drill and cleco the Delrin block bolt holes through the drilling template. Holes were drilled to #12 and then reamed to #10 Match drilling rivet holes into the doublers using the doubler drilling template as a guide After deburring th...