Alex's Vans RV-10 Build Log

Today I completed the Sheet Metal Basics practice kit that came with my RV-10 empennage kit that I received a few days ago. I compared this completed kit with another one I attempted a couple of months back to see if there were any differences. Overall, I think I did a better job this time around, or at least felt more comfortable working with the different tools, but this attempt was not without its gotchas outlined below. Read on... Starting pieces Skins drilled and match-drilled My first gotcha came when reaming holes from a #40 to a #30. On one of the holes, the reamer slipped out and slid across the surface of the skin making a very minor but visible scratch. I wouldn't worry about this if it was on an actual skin, but something to pay attention to. Angle piece cut and drilled... ...and match-drilled to skins All parts deburred, dimpled, countersunk, cleaned and ready for riveting My next two gotchas came in the final steps of skin preparation. The first was was when I was ups...

1st attempt at Van's Sheet Metal Basics practice kit. I didn't take many photos while assembling this kit, but here are a few of the finished product. Finished piece Front View I wasn't able to pull all the rivets along the bottom due to my manual rivet puller not gripping the stems properly (note the universal head rivets at the ends). Ordered an ATS pneumatic puller from Aircraft Spruce. Top (Outer Surface) View I'm happy with the way the outer surface looks. Side View Notice the pillowing between the two aluminum sheets Lessons Learned Start riveting outwards from the center of a rivet line to minimize pillowing between rivets Make sure to hold the sheets tightly together at corner rivets. The sheet corner tended to bend towards the shop head as I squeezed the rivets there I'll be trying another Sheet Metal Basics kit when one is delivered with my RV-10 empennage kit and comparing the results. Date: April 11 2022 Time Taken: 3.1 hours