775 hours have been put into this project and one year and five months have elapsed since I received the first kit.


It has been a very interesting and rewarding experience.

This is the wooden jig that Van's recommends constructing from the packing crates to place the rudder pedals correctly for setting the cable length. These guys are so very clever.


I have finished the rudder cables which required placing the fuselage on the bottom level of my work dolly to clear the low ceiling in my garage. This also enabled me to work on the canopy which is almost complete.



I also had an opportunity to sit in the cockpit, grab the joystick and make all sorts of airplane noises.


One part of the project that was unexpected required the construction of a fiberglass fairing at the base of the canopy aft of the front cowling. After some expert tutelage from Jeff Shutic, a master at resins and fiberglass, I came up with a pretty good result.



Another task is the assembly and sealing of the fuel tank. It is a smelly, sticky and unpredictable task. I would prefer to pay a couple of hundred bucks for a poly or welded aluminum tank. But it is what it is. So far I have everything but the top, vent tube, sight glass and sending unit plate sealed. That will take place soon.
Even the gas filler cap is slick!


The day came when I had to bring the wings back from storage and fit them to the fuselage. This goes without saying that it is pretty important that the wings fit.



My helpful nephew, Terry, assisted me. The wings weigh about 88 pounds but they are impossible to move by oneself. I rented the stake truck that Home Depot has available and with a jury-rigged tailgate extender, we were able to to transfer the two wings, flaperons and wing cart in three trips. Luckily my storage facility is only about a mile away.

The wings do fit, the flaperons flap and ailerate too. The Jesus pins go in, sometimes with some force but having someone jiggle the wings helps.

All that remains of the finishing kit is installing the landing gear and brakes and tires.

The engine and avionics will arrive next week but the Rotax engine sensors are on back order.

As of Easter Sunday, there are sixteen weeks until Oshkosh.

Well here I am again. To those of you who are patiently awaiting my updates, I am a dunce and a slow one at that.








The hardware in the picture is the Fiberglas tail cone material. It looks like this .. And this when completed...

I finished the engine cowling. Nothing very difficult but very tedious to sand-install-fit-remove-sand-install-fit-remove...you get the picture. I am pleased now that my airplane has a face


Even the little trapdoor for oil access came out well


It took 48 hours to finish the tail cone and engine cowling.
I then started on the fuel tank, preparing the metal but had to order the sealant. I switched instead to the electrical wiring. There seem to be a lot of wires in this plane. I will order the two-axis autopilot tomorrow when I place the order for the avionics kit. I included all of the optional wiring during the assembly

I tipped the fuselage on it's side and left off the turtle back and side skins. Good move on my part, suggested by both Jerry and Marty. Thanks guys. These guys really know how to blog.

I had a lot of trouble with the spar pins and the magnetic reed switches. This item should be improved to meet the elegance of design that the rest of the plane has. It is finicky and seems mickey mouse. I would have incorporated a micro switch. Anyway, after finally realizing that a reed switch was inoperative and a new one was received from Van's, I got that part completed.

I strung the rest of the wiring and installed the connectors for the autopilot. The bushings are full of wire. I don't think I can pass another strand of 22 gauge wire through some of them

Finally I wanted to install the joysticks. I passed the PTT switch wire through the joysticks.


But trouble arose when I tried to install them. The brass bushing used has an internal diameter of 0.245" on the print and the AN6 bolt has an external diameter of 0.247". This would be an interference fit of -0.002". Measuring the ID of the bushing shows it to be 0.241". This makes an interference fit of -0.006". Not going to work. A call to Van's is next.


At this point, I have 647 hours invested.

A wonderful coincidence occurred. At the suggestion of some of my fellow EAA chapter 127 members, I surfed the EAA website for technical counselors. I wanted a documentation trail of my build. Looking in the local Ohio section, I found a counselor in Oberlin Ohio. His name is Walter Edling. The first college I went to in 1965-66 was the Lorain County Community College and I received a degree in Mechanical Engineering Technology. One of my favorite professors was a Dr. Walter Edling. I figured this might be his son. When he answered the phone and I identified myself and asked him if he ever taught at LCCC he said "I remember you". So my old prof came over and was very supportive and complimentary about my build ethic and work shop. Dr. Edling is on the left. The other two are members of the EAA 255 chapter who wanted to see a RV 12.

Time for another blog update. It's obvious that I am not a good blogger but I hope I am a better airplane maker. I have made good progress these last ten weeks. Here are some photos of construction of the empennage.The bird finally has tail feathers and is starting to look like an airplane.

This photo of the anti-servo tab used for trim on the stabilator indicates the quality of the design of this plane. I've flown two other planes with this design, a Piper Warrior and a CT and I always wondered how they worked. Now I know.

The tail cone is being joined to the fuselage. This looks exactly like a photo taken in the Boing plant when they join the fuselage together for the 747, except a little smaller. My workforce is smaller too.

This is my total crew. Having a "sky hook" makes a lot of tasks much easier.

The fitting of the polycarbonate turtle deck back light. This started out to be very difficult until I remembered other bloggers stating that working with the canopy is safer and easier if the environment was warm. I inserted an electrical resistance heater in the baggage compartment and let the temperature stabilize around 99 F and over a three hour period, gradually inserted the clecoes until all of the holes lined up. Then match-drilled the roll bar, removed the polycarbonate and tapped the numerous holes to a 6-32 thread. My consummate skill as a lay machinist was at it's peak until I broke the tap off with only three holes to go. Luckily I was able to break the tap out and salvage the threaded hole. The bloggers also expressed concern about drilling holes in the polycarbonate. It has a tendency to fracture if the correct drill bit or technique is not used. I did purchase a special drill bit for drilling plastics and also brought an old hand powered drill at an antique show last month. The combination of those allowed a successful completion of enlarging the holes in the polycarbonate.

There she is, empennage kit complete. The wings, fuselage and empennage kits basically complete the structure of the airplane. The finishing kit has been ordered with expected arrival about 4-6 weeks. Then there is the avionics kit and the engine kit. Total build time to date has been 542 hours. Van's indicates about 600-900 hours to build sans paint. I won't make the 600 mark but might make the 900 mark.

It would be sweet to fly to Oshkosh next July...

Now at 391 total hours.

I just returned from a two week jaunt to Alaska and California visiting my two sons. Not a good excuse for being slow on updating this blog but it is the best I can come up with..

The fuselage kit needs only interior painting, some additional rivets, the 1/4" return fuel line and the fitment of the turtle deck backlight. This sounds like "just a few" items but I'm sure they will be demanding.

I intend to turn the fuselage on it's side which should then allow me to complete the fuel lines and commence interior painting while standing comfortably. Otherwise its like working over a deep bathtub.

No major problems have occurred to date, thanks to Marty's and Jerry's blogs and Van's most excellent plans. I've read their blogs prior to starting various sections and they have saved me much time and re-do work.

This section was much more complicated than the wing section - many more and different pieces. When the shipping box first arrived, it didn't seem like there was that much to it

Once the pieces and parts started to come out of it, the parts count grew tremendously.

I received a notice from Van's that kit#3, the empennage and tailcone was shipped three days ago. Perhaps it will be here by the Fourth of July. Gotta get busy.

I am looking forward to Oshkosh this year, especially if any pioneering RV12s might make it. I sure hope so.

I am intending to ride my Valkyrie to Wisconsin and spend three days and four nights (Wednesday - Friday).

I was able to sell my Zodiac rudder that I built at the Zenith rudder workshop through Barnstormers. The fellow who bought it says he has built a number of planes and flies an AT6.

I hope to meet Marty and Jerry and the rudder buyer in Oshkosh and any other interested aviation enthusiast. I'll be staying at Boelters adjacent to the ultralight area.

See you in Oshkosh.

Fuselage work continues. Three hundred and five hours have gone into the project. The lower fuselage from the firewall back to the end of the baggage/fuel tank floor area has been completed.

No major mistakes have been made to date but availing myself of the knowledgeable builder assist services at Vans has made my progress steady and uneventful.

I also am following Marty's and Jerry's builder blogs (very detailed and informative), intending to use their experiences to supplant my lack of knowledge. Of course, one of the times that I skipped reading their blogs prior to a major assembly point, I realized I should have.

I had already attached the lower front fuselage to the middle section and then I read Marty's blog. He stated that it would be much better to attach the F1207 E&L vertical supports to the front of the middle section before attaching the front section to it.

Oops!

The problem is that there is minimal room to get a rivet puller in the tight area after the front section is attached. There are four rivets for each vertical support. The rivets can be inserted but due to the curvature of the belly skin, there is no room for a straight pull.

I had already made an angle plate to allow pulling rivets when they are too close to a bulkhead to permit a straight pull. I made a much smaller version and used a small, 40-year old Montgomery Ward rivet puller to successfully pull all eight rivets flush and square. Hooray!

The next step is bending the aluminum angle longerons to fit the curvature of the mid-fuselage.

Fuselage work continues...

At this point, I am at 245 hours of build time and just finished attaching the seat assembly ribs to the center section bulkhead.

This section of assembly is more detailed and varied from the wings portion. There are many more parts, fasteners and hardware pieces that have to be identified and used.

I did a thorough inventory of all parts short of counting the quantity of different rivets and then listed the location of each bag of hardware and miscellaneous parts as I secreted them throughout the house. The spare bath tub is an excellent repository for big pieces and buckets of little parts. Under the bed has space for large panels and long pieces.

There are two other RV12 bloggers (Marty's RV 12 and Jerry Greenburg's RV12) who have created blogs that are terrific for their detail and content. They are far ahead of me and I often read over what they have done in the section I am working on. In fact, if I would have read Marty's blog yesterday before I cut the hinge sections for the seat backs, I wouldn't have messed it up and might now have to buy more hinge material.

At 191 hours the flaperons are completed. It took longer then I thought it should but then again, I never did anything like this before. The error I made with the pivot attach brackets was corrected by ordering a new piece of AEX and building new brackets. The comparison photos showing the offset original bracket position to the now corrected bracket makes it worth it. It took about 11 hours total to repair.

The only other problem occurred when riveting the A1207 actuation brackets. The rivet squeezer was too large to allow the manufactured head to sit in the die pocket and the shop head to be formed correctly. The holes were too close to the angle of the bracket. I fabricated a shop head die holder from a piece of 1/2 thick steel and clamped it in a vise. This allowed me to form the shop head with a punch making it flat and square.

The fuselage is next.