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 Landing Gear Fairings http://xeno.org/~mackd/rv/?action=log&id=552 http://xeno.org/~mackd/rv/?action=log&id=552 Sun, 11 Feb 2024 17:08:27 +0000 mackd <p>Hours: 0.67</p> <p>Today I drilled the halves of the two wheel fairings together, making a left and a right in the process.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/11/rv1_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/11/rv2_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I then spent a little while leveling the fuselage for fitting these fairings.</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> Landing Gear Fairings http://xeno.org/~mackd/rv/?action=log&id=551 http://xeno.org/~mackd/rv/?action=log&id=551 Sat, 10 Feb 2024 17:05:48 +0000 mackd <p>Hours: 1.18</p> <p>Today I finished sanding the halves for fit and then taped them together. I did my best to draw an accurate centerline using some string to help guide me. I also drew lines for drilling the halves together.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/10/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> Landing Gear Fairings http://xeno.org/~mackd/rv/?action=log&id=550 http://xeno.org/~mackd/rv/?action=log&id=550 Thu, 08 Feb 2024 19:10:45 +0000 mackd <p>Hours: 1.33</p> <p>This layup set up, so I sanded it down. Then I fit the two halves together of this wheel fairing and did a bit more sanding until I was happy with it.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/08/rv1_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I released the gear leg fairings from the gear legs, sanded the rough areas from the reinforcement layup on the tabs, and then mounted them back on the legs with the worm gear clamps. This looks like it should work fairly well.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/08/rv2_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Then, I did some more sanding on the other wheel fairing. Slow, iterative work that I don't particularly enjoy.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/08/rv3_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> Landing Gear Fairings http://xeno.org/~mackd/rv/?action=log&id=549 http://xeno.org/~mackd/rv/?action=log&id=549 Mon, 05 Feb 2024 17:40:28 +0000 mackd <p>Hours: 3.50</p> <p>I sanded the filler from the left gear leg fairing. Once it's painted, nobody will ever know about the extra holes.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/05/rv1_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Then I carefully marked and notched the upper ends of the gear leg fairings for where they clamp to the gear legs.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/05/rv2_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Then I cut out two layers of fiberglass cloth per notch and laid them up with epoxy for added strength per the plans.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/05/rv3_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Then I installed them on the gear legs to cure to the curved shape. It does not look centered here, but it is.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/05/rv5_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Then I started working on one of the pairs of wheel fairings, doing lots of sanding to improve the fit. The flange on one side of the aft fairing was way too deep, so I put down a layer or two of fiberglass and then built up some thickness with epoxy/flox.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/05/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> Landing Gear Leg Fairings http://xeno.org/~mackd/rv/?action=log&id=548 http://xeno.org/~mackd/rv/?action=log&id=548 Sun, 04 Feb 2024 20:23:23 +0000 mackd <p>Hours: 2.67</p> <p>I trimmed another strip off of the trailing edge of the first leg fairing and then sanded it. I think this will be the final cut.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/04/rv2_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I also cut and bent the hinge pin. I will drill a small #40 hole for safety wire to secure the pin.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/04/rv1_th.jpg" style="width:375px;height:500px;" alt=""></a> </p> <p>Here's proof of how flush the trailing edge is. Perfect! To achieve this, I had to sand some extra epoxy from the inner surfaces that was there from the initial fabrication at the factory.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/04/rv3_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I installed the hinge in the second gear leg fairing. This time, with my experience yesterday, it came out perfectly the first time.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/04/rv4_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I also mixed up some epoxy with micro and filled all of the holes in the first fairing. I'll sand this tomorrow.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/04/rv5_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Here's the second fairing in place on the right gear leg. Looks pretty good.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/04/rv6_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I cut the trailing edges to be the same dimension.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/04/rv7_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Then, I started reading through the instructions for the wheel fairings and put them together to see how they fit. There will be a lot of work to get these to nest properly.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/04/rv8_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> Landing Gear Leg Fairings http://xeno.org/~mackd/rv/?action=log&id=547 http://xeno.org/~mackd/rv/?action=log&id=547 Sat, 03 Feb 2024 20:11:12 +0000 mackd <p>Hours: 5.00</p> <p>Before I got started today, I looked up the instructions for the RV-14 gear leg fairings and discovered a few tricks. One of those is to drill five holes through the flange of the trailing edges to hold them in their untwisted state rather than using tape. This makes life easier, because it's simple and fast to cleco and uncleco as needed.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/03/rv1_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I trimmed the upper and lower ends to the lines from the template, but they were still a bit too long.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/03/rv2_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>So I took an extra inch off of the bottom of both of them.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/03/rv3_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Next, I placed the hinge in one of the fairings where I thought I wanted it to sit, marked lines on the fairing and hinge, and then drilled holes through the fairing.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/03/rv4_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Then, I clamped one half of the hinge in place and drilled it using the holes in the fairing as a guide.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/03/rv5_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Then, I installed the other half of the hinge with the pin, as well as the trailing edge clecos, and drilled the other half of the hinge to the fairing.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/03/rv6_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Unfortunately, my positioning of the hinge was too far aft in such a way that the trailing edge was not drawn together as it should be.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/03/rv7_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I considered trying to use heat to pull the trailing edge flanges together, but in the end I decided to re-drill all of the holes. I moved the hinge forward about 3/8" to a spot that seemed to pull the trailing edge together. I used the same piece of hinge, just shifting it about 3/4" so the new holes would be far from the old ones. I repeated the whole process with the drilling and things looked much better.</p> <p>I countersunk the holes and then riveted both sides of the hinge in place. I also trimmed off a lot of the extra trailing edge flange. I will probably remove a bit more, still.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/03/rv8_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I put it in place on the plane to see how it works and looks. I'm pretty happy with it. I neglected to take a picture, but the trailing edge pieces are flush with each other. The fairing is slightly snug against the landing gear rod. I'll put some UHMW tape on the rod per the instructions to help with that.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/03/rv9_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Left to do: cut out the notches on the top end for the worm gear clamps, cut the hinge pin to length, trim a bit more from the trailing edge, and fill the holes from my first attempt at drilling. Not to mention, I need to install the hinge on the other fairing.</p> <p>I also ordered some pre-made intersection fairings today.</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> Landing Gear and Leg Fairings, Brakes and Lines http://xeno.org/~mackd/rv/?action=log&id=546 http://xeno.org/~mackd/rv/?action=log&id=546 Fri, 02 Feb 2024 19:17:58 +0000 mackd <p>Hours: 5.25</p> <p>A few days ago I installed the diodes on the solenoids.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/02/rv01_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I had ordered custom length hoses for the connection from the brake master cylinders to the firewall. After taking this shot, I zip tied the two together and installed some UHMW tape on the rudder pedal weldments where the hoses were rubbing.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/02/rv02_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I reinstalled the landing gear legs into the engine mount, bolted and torqued them.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/02/rv03_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I reinstalled the wheels, brake calipers, and fairing brackets.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/02/rv04_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>The other side.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/02/rv05_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I installed the forward brake line on the left side per the plans. I used some 1/4" ID vinyl tubing as stand-off for the line from the engine mount and gear legs. Inside the engine compartment, I used high temp zip ties and on the gear legs, electrical tape.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/02/rv06_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>For the right brake line, I secured it to the engine mount with the vinyl tubing as stand-off and high temp zip ties to secure them.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/02/rv07_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Here's a close-up of how the tubing is secured to the gear leg.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/02/rv09_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>And a close-up of the engine mount securement.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/02/rv10_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Now, I need to get some of the appropriate flavor of brake fluid and the equipment to bleed the brakes.</p> <p>Today, I pulled out the gear leg fairings and started working on them. I spent several hours trying to make sure they had no twist in them. Some of the time was simply learning what I was doing trying to measure the twist and some was repeatedly taping the trailing edges together in a twist-free way.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/02/rv11_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>After a lot of struggle, I got them both to where I wanted them.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/02/rv12_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Then, I cut out the template and transferred the appropriate RV-7 measurements to both of the fairings.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2024/02/02/rv13_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Next up: trim the fairings to the cut lines.</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> Firewall Forward Misc http://xeno.org/~mackd/rv/?action=log&id=545 http://xeno.org/~mackd/rv/?action=log&id=545 Thu, 21 Dec 2023 09:58:50 +0000 mackd <p>Hours: 1.75</p> <p>I installed these two one legged nutplates along the top of the firewall recess.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2023/12/21/rv1_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Then I installed the cabin heat pass-through with fire barrier sealant.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2023/12/21/rv2_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I riveted the firewall recess in place. I managed to drop my bucking bar and cause a ding on the floor of the cabin. Ugh. Fortunately it won't ever be seen by anyone.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2023/12/21/rv3_th.jpg" style="width:375px;height:500px;" alt=""></a> </p> <p>I filled the holes in the recess with sealant and bolted the battery box in place.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2023/12/21/rv4_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I drilled and bolted this manifold for various pressure measurements.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2023/12/21/rv5_th.jpg" style="width:375px;height:500px;" 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> Firewall Forward Misc http://xeno.org/~mackd/rv/?action=log&id=544 http://xeno.org/~mackd/rv/?action=log&id=544 Sun, 10 Dec 2023 17:23:57 +0000 mackd <p>Hours: 2.88</p> <p>I got back out to the plane today, finally. I touched up the paint on the battery box a little bit where the hole saw had opened up the aluminum.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2023/12/10/rv1_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I recently got the battery and starter solenoids, so I drilled the holes that I had left in the doubler plate, riveted on the nutplates, and then riveted the doubler to the firewall.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2023/12/10/rv2_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Here are the solenoids in place.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2023/12/10/rv3_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I made the 2" hole for cabin heat using a hole punch.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2023/12/10/rv4_th.jpg" style="width:375px;height:500px;" alt=""></a> </p> <p>Then I drilled the bolt/screw holes for the cabin heat shutter and loosely bolted it in place. I need to put some sealant between the shutter and the firewall before I bolt it on permanently.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2023/12/10/rv6_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I drilled and enlarged the 5/8" hole for the throttle cable.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2023/12/10/rv7_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I also drilled and enlarged the 5/8" holes for the mixture and prop cables.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2023/12/10/rv8_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> Cockpit Fit Testing, Panel Planning, Left Seatback Modification http://xeno.org/~mackd/rv/?action=log&id=543 http://xeno.org/~mackd/rv/?action=log&id=543 Fri, 27 Oct 2023 20:28:31 +0000 mackd <p>Hours: 1.83</p> <p>I'd recently gotten it in my head to do a fit test in my plane with the seats and my canopy. I'm tall, at 6'5", but I had done a fit test in the Van's RV-7 at Oshkosh before I started building, so I wasn't tooooo worried.</p> <p>I put the panel in place, temp installed the canopy, and put the upholstered seat back and seat cushion in the plane.</p> <p>I positioned the rudder pedals somewhere close to neutral and placed one of the vent brackets in place. Leg room seems good...my knees don't come too close to the panel or vent brackets.</p> <p>At this stage, it's a very compact and tight panel with a lot of functionality. I'm sure I'll make a few more changes, but I'm quite happy with it at.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2023/10/27/rv1_th.jpg" style="width:375px;height:500px;" alt=""></a> </p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2023/10/27/rv2_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>Head space is another matter. I fit...but just barely. There would definitely be no space for the band on my headset. If I sit up straight, my head touches the canopy. This picture doesn't do a great job of showing the issue.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2023/10/27/rv3_th.jpg" style="width:375px;height:500px;" alt=""></a> </p> <p>I'm going to attack this issue from two directions. First, I pulled out the seat back brace and just let the aluminum seat rest against the bulkhead, which gives me a little more aft "lean" to the seat and helps a bit with the head to canopy spacing. Second, I'm going to order another seat bottom cushion with 0.5" less memory foam, which should get me a little bit further from hitting my head. I may still end up having to use a "no headband" headset like the CQ1 in-ear headset, but we will see.</p> <p>Having settled on not using the seat back brace, I decided to modify my left-side seat-back to permanently rest against the bulkhead. I drilled out the hinge from the seat back brace.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2023/10/27/rv5_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>In place of the hinge, I installed a piece of angle with a couple of spacers on the outside edges where the seat will contact the bulkhead. This gives two strong points for the seat to contact the bulkhead and lifts the seat away from the canopy latch weldment that runs right between the seat and bulkhead. It also prevents the shop heads of the blind rivets from touching the bulkhead.</p> <p>I'll leave the right-side seat in the normal configuration where the seat back brace is inserted into a tight slot on top of the bulkhead; that way it won't move when I'm flying solo. I don't expect many, if any, of my passengers to be as tall as I am.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2023/10/27/rv6_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I've also been working on designing my panel. I've basically settled on a Garmin G3X system with two 10" displays as well as a G5 for backup. In the center will be a GTN 650xi GPS navigator and a GTR200 backup/secondary radio in addition to an audio panel and the G3X autopilot panel. I started with a pretty basic layout on the actual panel using printouts and drawing in the spots where I thought the switches would go.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2023/10/27/rv4_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I needed something much more precise and easier to move around, though, so I started a project in CAD. I don't have any CAD experience, so this was all learning on the fly. There were quite a few issues to work through with this.</p> <p>First, the RV-7 panel CAD files from Van's are great, but they don't tell you that they represent the unbent panel (before the lower edge is bent around for stiffness). So I had a whole panel designed with an extra inch of space on the bottom. I'm not interested in extending my panel down (which lots of people do), because I want to preserve as much legroom as possible. So that required a lot of adjusting.</p> <p>The other major issue for me is the canopy frame. You may recall from earlier in my log that the forward canopy frame weldment had extremely poor fit. Specifically, the welded tube did not conform to the canopy skin. This is a common problem, but I think my fit is worse than average. I did what most people do and just skipped riveting some of the skin rivets to the frame. The only issue is that the frame takes a bit of a "dive" across the front of the instrument panel when the canopy is closed. You can see this in the above picture.</p> <p>The fit with the 10" garmin screens is pretty tight when I leave enough space for a row of switches at the bottom. The canopy frame issue made this even tighter because it meant I had to squeeze the screens down and toward the middle to get them away from the frame. You can see in the CAD drawing below where I've illustrated how far the canopy frame comes over the panel. Fortunately, it's less of an issue on the left side than the right, so I was able to shift everything to the left (toward the pilot) and eventually make it all work.</p> <p>One unconventional modification I've included is to move the throttle, prop, and mixture controls up onto the panel. Typically, these sit below the panel on another bracket, but I wanted to preserve as much leg room as a I could.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2023/10/27/rv8_th.jpg" style="width:500px;" alt=""></a> </p> <p>Finally, I laid it all out with printouts of the avionics and schematics of the switches and control cables. It's nice to sit in the plane and do a little imagining...</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2023/10/27/rv7_th.jpg" style="width:500px;height:375px;" alt=""></a> </p> <p>I ended up using a lot of SPST switches in this panel. I could certainly have consolidated to fewer switches by using multiple position switches or combining functionality (e.g. combining the alternator switches into one). However, in my mind, the point of having a backup battery or alternator is redundancy. If both alternators use a single switch and that switch fails, then I've lost both of those items. Since I have the space, I like the idea of having separate switches and a few less single points of failure.</p> <p>I've also elected to skip the keyed switch for the PMAGs and starter that are popular in many light aircraft. Again...it's a single point of failure that could take out the engine. Instead, I have two switches for PMAG grounding (which turns them on or off), two switches for PMAG testing (d/c them from ship power to test the built in generators), and a separate starter switch.</p> <p>By the way, I worked up this power plan for the plane a year ago or so and thought I'd toss it in here so there's a record of it in this log.</p> <p style="text-align:center;"> <a http://xeno.org/~mackd/rv/href=""><img src="2023/10/27/rv9_th.jpg" style="width:500px;" alt=""></a> </p> <p><i>Only actual building work on the seat back was counted toward this log entry. None of the planning or fit testing time is included.</i></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>