David Mack's RV-7 Project http://xeno.org/~mackd/rv/ A log of my experience building a Van's RV-7 in my garage. en-us Air Filter Bracket, Baffles http://xeno.org/~mackd/rv/?action=log&id=603 http://xeno.org/~mackd/rv/?action=log&id=603 Thu, 20 Jun 2024 19:00:39 +0000 mackd <p>Hours: 4.00</p> <p>I removed the propeller today. Now that the cowl is fitted, there's no need for it and I just risk damaging it while it's out. It will also be easier to install the lower cowl to test baffle fit.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/20/rv1_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I sanded the airbox, both inside and outside, where I had laid up the extra fiberglass yesterday.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/20/rv2_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I cut out the opening in the left inlet floor for the air intake.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/20/rv3_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Making brackets for the air filter bracket...</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/20/rv4_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Brackets drilled to the airbox. I had to order a new one for the aft side, because I trimmed it too much before I realized that the flanges sit inside the airbox rather than outside.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/20/rv5_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I reinstalled the lower cowl and started marking cowl inlets and inlet floors for trimming.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/20/rv6_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <br><br> <p>See more about my RV-7 aircraft project at my website: <a href="http://xeno.org/~mackd/rv/">http://xeno.org/~mackd/rv/</a>.</p> <table> <tr><td> <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/"><img alt="Creative Commons License" style="vertical-align: top; border-width:0;" src="http://creativecommons.org/images/public/somerights20.png" /></a> </td><td> <span style="font-size: 9pt;"> Unless otherwise stated, this content, created by David Mack, is licensed under a <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/">Creative Commons Attribution-Noncommercial-No Derivative Works 3.0 Unported License</a>. </span> </td></tr> </table> Airbox Fitting http://xeno.org/~mackd/rv/?action=log&id=602 http://xeno.org/~mackd/rv/?action=log&id=602 Wed, 19 Jun 2024 17:33:05 +0000 mackd <p>Hours: 0.75</p> <p>I marked some areas on the airbox where it comes close to touching the starter, cylinder #2 intake, and cylinder #2 oil return line. I roughed these areas up on the inside with 60 grit sandpaper.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/19/rv1_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Then I laid up 3 layers of fiberglass over each of these areas and I'll plan to sand down the outside to increase clearance to those obstacles.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/19/rv2_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I also spent some time looking at the oil cooler and routing for an air duct. I'm using a larger oil cooler because I have the angle valve IO-360, so it won't fit on the baffles. I'm planning to place it on the firewall, but that means ducting air from the baffles to the cooler.</p> <br><br> <p>See more about my RV-7 aircraft project at my website: <a href="http://xeno.org/~mackd/rv/">http://xeno.org/~mackd/rv/</a>.</p> <table> <tr><td> <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/"><img alt="Creative Commons License" style="vertical-align: top; border-width:0;" src="http://creativecommons.org/images/public/somerights20.png" /></a> </td><td> <span style="font-size: 9pt;"> Unless otherwise stated, this content, created by David Mack, is licensed under a <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/">Creative Commons Attribution-Noncommercial-No Derivative Works 3.0 Unported License</a>. </span> </td></tr> </table> More New Rudder Work, Air Box Trimming and Fitting http://xeno.org/~mackd/rv/?action=log&id=601 http://xeno.org/~mackd/rv/?action=log&id=601 Mon, 17 Jun 2024 18:51:15 +0000 mackd <p>Hours: 4.00</p> <p>I finished riveting the rudder stiffeners to the skin.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/17/rv2_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Then I started assembly the rudder skeleton, including fabricating a few parts and trimming some others.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/17/rv1_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I need to build a bending brake out of some 2x8s again...dunno what I did with my last one.</p> <p>Then I got back to work on the air box. I sanded the top where I had extended it with additional fiberglass and then used the inlet floor to trim it to proper length.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/17/rv3_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I also drilled the bolt holes to connect it to the fuel servo and trimmed the excess from the flange at the bottom.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/17/rv4_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>The airbox sits a little bit too close to the starter and the cylinder #2 oil drain line, so I'm going to need to add some "bump ins" in those areas to increase clearance.</p> <br><br> <p>See more about my RV-7 aircraft project at my website: <a href="http://xeno.org/~mackd/rv/">http://xeno.org/~mackd/rv/</a>.</p> <table> <tr><td> <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/"><img alt="Creative Commons License" style="vertical-align: top; border-width:0;" src="http://creativecommons.org/images/public/somerights20.png" /></a> </td><td> <span style="font-size: 9pt;"> Unless otherwise stated, this content, created by David Mack, is licensed under a <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/">Creative Commons Attribution-Noncommercial-No Derivative Works 3.0 Unported License</a>. </span> </td></tr> </table> Cowl Reflective Tape, More New Rudder Work http://xeno.org/~mackd/rv/?action=log&id=600 http://xeno.org/~mackd/rv/?action=log&id=600 Sun, 16 Jun 2024 18:44:26 +0000 mackd <p>Hours: 5.33</p> <p>Today I applied the heat insulation to the bottom cowl where it's close to the exhaust.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/16/rv1_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Then I applied reflective silver tape to the edges to keep it from peeling over time.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/16/rv2_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I got all of the rudder stiffeners polished up on the trim lines.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/16/rv3_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Then I drilled, deburred, and dimpled all of the holes from stiffeners to skin. I primed the bottoms of the stiffeners. Finally, I riveted most of the stiffeners to the rudder skin. It's been a long time since I did any back riveting.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/16/rv4_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <br><br> <p>See more about my RV-7 aircraft project at my website: <a href="http://xeno.org/~mackd/rv/">http://xeno.org/~mackd/rv/</a>.</p> <table> <tr><td> <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/"><img alt="Creative Commons License" style="vertical-align: top; border-width:0;" src="http://creativecommons.org/images/public/somerights20.png" /></a> </td><td> <span style="font-size: 9pt;"> Unless otherwise stated, this content, created by David Mack, is licensed under a <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/">Creative Commons Attribution-Noncommercial-No Derivative Works 3.0 Unported License</a>. </span> </td></tr> </table> Baffles, Airbox, Cowl, Started New Rudder http://xeno.org/~mackd/rv/?action=log&id=599 http://xeno.org/~mackd/rv/?action=log&id=599 Sat, 15 Jun 2024 12:33:51 +0000 mackd <p>Hours: 4.00</p> <p>I bent the forward end of the right front baffle side and then riveted the reinforcement plates to the two right side baffle plates. I also clamped the forward center baffle pieces in place to see how they fit into everything else.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/15/rv7_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I fabricated a 3" round piece of plywood to use to center the airbox on the fuel servo.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/15/rv2_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Then I test fit the airbox.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/15/rv1_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>It turned out the gap up to the left front intake floor was too much, so I added some height to the airbox top end in those areas.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/15/rv3_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I installed the right front air dam in front of the #1 cylinder to the baffle system.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/15/rv4_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I trimmed some length from the lower cowl inlets to try to get it to be easier to install with the baffle floors in place. This will still require some iterative trimming.</p> <p>I laid down some thinned epoxy mixture on the cowl bottom where I intend to install the adhesive reflective coating. I limited this to areas that are relatively close to the exhaust pipes.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/15/rv5_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I decided to rebuild my rudder...I'm not a fan of how much oil canning the my old one has. There's also some questioning online about the strength of the large RV-9 style rudder that the RV-7 uses--it was originally designed to use the same rudder as the RV-8, but spin recovery was slightly slow, so they changed it. There have been a fair number of structural failures of RV-7 where the rudder seems to have been the first part to fail, although admittedly all of them were going significantly over V<sub>NE</sub> at the time. There doesn't seem to have been any similar failure of the RV-8 style rudder.</p> <p>Still, these two factors combined to convince me to rebuild it and use the RV-8 rudder this time. The primary differences are that the RV-8 rudder is smaller and uses a single skin bent trailing edge design rather than the two piece with a wedge that the RV-7/9 design uses. Fortunately they fit identically to the vertical stabilizer other than the fiberglass fairing up at the top that I will have to swap out.</p> <p>I snipped out all of the stiffeners and started trimming them.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/15/rv6_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <br><br> <p>See more about my RV-7 aircraft project at my website: <a href="http://xeno.org/~mackd/rv/">http://xeno.org/~mackd/rv/</a>.</p> <table> <tr><td> <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/"><img alt="Creative Commons License" style="vertical-align: top; border-width:0;" src="http://creativecommons.org/images/public/somerights20.png" /></a> </td><td> <span style="font-size: 9pt;"> Unless otherwise stated, this content, created by David Mack, is licensed under a <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/">Creative Commons Attribution-Noncommercial-No Derivative Works 3.0 Unported License</a>. </span> </td></tr> </table> More Baffles http://xeno.org/~mackd/rv/?action=log&id=598 http://xeno.org/~mackd/rv/?action=log&id=598 Tue, 11 Jun 2024 05:52:25 +0000 mackd <p>Hours: 2.50</p> <p>I added this little tab in the back corner of the left front inlet floor to pull the side baffle tight.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/11/rv1_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I started working on the right front inlet floor. This took a lot of iteration again. The other complication is that the oil line for the propeller comes right up through this, so there has to be a big 1" hole for it to pass through, which you can see here.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/11/rv2_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <br><br> <p>See more about my RV-7 aircraft project at my website: <a href="http://xeno.org/~mackd/rv/">http://xeno.org/~mackd/rv/</a>.</p> <table> <tr><td> <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/"><img alt="Creative Commons License" style="vertical-align: top; border-width:0;" src="http://creativecommons.org/images/public/somerights20.png" /></a> </td><td> <span style="font-size: 9pt;"> Unless otherwise stated, this content, created by David Mack, is licensed under a <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/">Creative Commons Attribution-Noncommercial-No Derivative Works 3.0 Unported License</a>. </span> </td></tr> </table> More Baffles, Cowl Sanding http://xeno.org/~mackd/rv/?action=log&id=597 http://xeno.org/~mackd/rv/?action=log&id=597 Mon, 10 Jun 2024 18:49:10 +0000 mackd <p>Hours: 3.00</p> <p>I spent some time today sanding down the bottom cowl where there was excess epoxy/flox spread from the hinges.</p> <p>Then I worked some more on the left inlet floor. I got the outboard angle drilled to the side baffle and the angle that sits in front of the cylinder drilled.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/06/10/rv1_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <br><br> <p>See more about my RV-7 aircraft project at my website: <a href="http://xeno.org/~mackd/rv/">http://xeno.org/~mackd/rv/</a>.</p> <table> <tr><td> <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/"><img alt="Creative Commons License" style="vertical-align: top; border-width:0;" src="http://creativecommons.org/images/public/somerights20.png" /></a> </td><td> <span style="font-size: 9pt;"> Unless otherwise stated, this content, created by David Mack, is licensed under a <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/">Creative Commons Attribution-Noncommercial-No Derivative Works 3.0 Unported License</a>. </span> </td></tr> </table> More Baffles http://xeno.org/~mackd/rv/?action=log&id=596 http://xeno.org/~mackd/rv/?action=log&id=596 Thu, 30 May 2024 18:47:21 +0000 mackd <p>Hours: 2.00</p> <p>Worked for a while more today on getting the left inlet floor baffle fitted.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/05/30/rv1_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Got the inboard brackets drilled.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/05/30/rv2_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <br><br> <p>See more about my RV-7 aircraft project at my website: <a href="http://xeno.org/~mackd/rv/">http://xeno.org/~mackd/rv/</a>.</p> <table> <tr><td> <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/"><img alt="Creative Commons License" style="vertical-align: top; border-width:0;" src="http://creativecommons.org/images/public/somerights20.png" /></a> </td><td> <span style="font-size: 9pt;"> Unless otherwise stated, this content, created by David Mack, is licensed under a <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/">Creative Commons Attribution-Noncommercial-No Derivative Works 3.0 Unported License</a>. </span> </td></tr> </table> More Baffles http://xeno.org/~mackd/rv/?action=log&id=595 http://xeno.org/~mackd/rv/?action=log&id=595 Tue, 28 May 2024 18:46:18 +0000 mackd <p>Hours: 1.00</p> <p>Started to get the left inlet floor baffle mounted today. It took quite a bit of trimming to get it to fit next to the crankcase.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/05/28/rv1_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <br><br> <p>See more about my RV-7 aircraft project at my website: <a href="http://xeno.org/~mackd/rv/">http://xeno.org/~mackd/rv/</a>.</p> <table> <tr><td> <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/"><img alt="Creative Commons License" style="vertical-align: top; border-width:0;" src="http://creativecommons.org/images/public/somerights20.png" /></a> </td><td> <span style="font-size: 9pt;"> Unless otherwise stated, this content, created by David Mack, is licensed under a <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/">Creative Commons Attribution-Noncommercial-No Derivative Works 3.0 Unported License</a>. </span> </td></tr> </table> Cowl Sanding, Hinges, Baffle Installation http://xeno.org/~mackd/rv/?action=log&id=594 http://xeno.org/~mackd/rv/?action=log&id=594 Mon, 27 May 2024 18:25:17 +0000 mackd <p>Hours: 7.50</p> <p>I sanded out the top cowl inlet ducts nice and smooth.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/05/27/rv1_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Then I sanded down the extensions on the sides of the lower cowl and trimmed them up until they were the appropriate length. Looks good on the right side.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/05/27/rv2_th.jpg" style="width:375px;height:500px;" alt=""></a> </p> <p>And on the left side.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/05/27/rv3_th.jpg" style="width:375px;height:500px;" alt=""></a> </p> <p>Then I countersunk all the holes, prepared the hinges, and riveted them all in place with epoxy/flox.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/05/27/rv4_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Then I got back to work on the baffles. I drilled the rear baffles to the side baffles at the left and right rear corners. I also drilled the two pieces of the rear left side together.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/05/27/rv5_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I also installed the bracket at the rear center that connects the baffles to the crankcase.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/05/27/rv6_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I also installed the little bracket on the right rear baffle section to the crankcase. It looks like the outboard sections of my cylinder fins are not exactly the shape expected by the contour of the "cylinder wrap" parts of the rear and forward baffle sections. I'm going to have to re-bend these a bit.</p> <p>I stared at the plans and the pieces for the inlet section of the baffles for a while before deciding to leave it for another day.</p> <br><br> <p>See more about my RV-7 aircraft project at my website: <a href="http://xeno.org/~mackd/rv/">http://xeno.org/~mackd/rv/</a>.</p> <table> <tr><td> <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/"><img alt="Creative Commons License" style="vertical-align: top; border-width:0;" src="http://creativecommons.org/images/public/somerights20.png" /></a> </td><td> <span style="font-size: 9pt;"> Unless otherwise stated, this content, created by David Mack, is licensed under a <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/">Creative Commons Attribution-Noncommercial-No Derivative Works 3.0 Unported License</a>. </span> </td></tr> </table>