Van's Aircraft RV-8, Construction Manual

Page 1: ...VAN S RV 8 8A CONSTRUCTION MANUAL VAN S AIRCRAFT INC 14401 KEIL ROAD AURORA OREGON USA 503 678 6545 FAX 503 678 6560 www vansaircraft com support vansaircraft com...

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Page 3: ...airworthiness of the airframe and or powerplant Technical support may not be available for modifications that deviate from the plans nor for installations that are not specifically recommended by Van...

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Page 5: ...ilders should contact the appropriate agencies of their governments for regulations that pertain to them VAN S BUILDER ASSISTANCE Van s offers builders assistance on the telephone between the hours of...

Page 6: ...t chord wing planform chosen for the RV 3 4 6 7 8 series offers the ultimate in construction ease stability and lifting ability The possible drag and aesthetic penalties for the rectangular wing are n...

Page 7: ...n or the line pressure An inexpensive air flow regulator installed at the air inlet of the gun is essential on these lower quality guns and is a useful accessory on the better guns as well Many air ch...

Page 8: ...ood quality dimpling and setting is simple The depth of the C frame is sufficient to dimple almost all the skins on RVs It is rigid enough to permit setting rivets up to 3 16 inch dia so some builders...

Page 9: ...90 Drill REQ RV 14 1 1 4 28 Tap 1 5 16 24 Tap 1 3 8 16 Tap 1 3 8 24 Tap 1 4 40 Tap 2 6 32 Tap 1 8 32 Tap 1 10 24 Tap CATEGORY QTY ITEM Required Optional Dimpling Riveting 1 Dimple Die Reduced diam 3...

Page 10: ...ealant Optional 1 Socket Set 1 4 3 8 Drive 4 3 8 dia Drift Pin Fabricate from hardw are store bolts by tapering the end CATEGORY QTY ITEM Required Optional Ref Mat ls Supplies 1 A C STRUCTURAL TECHNIC...

Page 11: ...ank U Undercarriage WD Weldment C Canopy 2 The first numbers in RV models 3 4 6 and 6A 7 and 7A 8 and 8A 9 and 9A and 10 were allocated in blocks of 100 for our various models Thus most 800 series num...

Page 12: ...ionship of other parts of the structure without the clutter of an assembly drawing Bend Line Indicates the line about which a bend is to be made Section Line This is used to indicate a view of a part...

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Page 21: ...6 5F BACK RIVETING 5 7 5G FOLDED TRAILING EDGES 5 7 5H RIVETED TRAILING EDGES 5 9 5J ROLLED LEADING EDGES 5 10 5K LAP JOINTS LETTER 5 11 5L FORMING ALUMINUM PARTS FROM SHEET 5 12 5M VINYL COATING 5 1...

Page 22: ...UL approved respirator must be used A simple particle filter is just not good enough Keep in mind that many paint systems now contain chemicals for which a conventional filter type respirator is not...

Page 23: ...head from seating properly and can make dimple countersunk holes more prone to developing cracks radiating from the hole Many novice builders deburr excessively deep Deburring should not produce a si...

Page 24: ...l still meet the MIL Spec requirement This is done to avoid using a rivet size that may be slightly long and more difficult to properly install NOTE There are times when the correct rivet length is no...

Page 25: ...Artwork by Tony Bingelis FIGURE 1 RIVETING PROCESS NOMENCLATURE COMMONLY ENCOUNTERED PROBLEMS PAGE REVISION DATE VAN S AIRCRAFT INC 05 05 RV ALL 3 01 17 14...

Page 26: ...INC PAGE REVISION DATE 2 RV ALL 05 06 04 15 13 VA 140 1 2 5 16 REMOVE HATCHED AREA 1 4 5 4 continued METHODS FOR SETTING RIVETS FABRICATING THE WEDGE TOOL The wedge tool provides assistance when blind...

Page 27: ...PROPER INSTALLATION Step 1 Verify tool and CHERRYMAX rivet compatibility by performing a test on an easily removed rivet in the event that removal becomes necessary For removal see the CHERRYMAX Proce...

Page 28: ...w as a gauge when you machine countersink Stop when the rivet or screw is flush For a dimpled skin riveted onto a machine countersunk surface the countersink must be slightly deeper as mentioned earli...

Page 29: ...edure extensively in our own shop FIGURE 1 BACK RIVETING OVERHANG PROVIDES HANDLES FLAT 2 X 8 BOARDS FIGURE 2 HOMEMADE BENDER DOOR HINGES SKIN MANF HEAD RIVET GUN WITH FLAT OR BACK RIVET SET STEEL PLA...

Page 30: ...to completely finish the bend in areas where stiffeners or ribs are located Correct or un squeeze an over bent TE using another wood block as shown in Figure 6 Again put a large radius taper on each...

Page 31: ...ilot Position the strips so that the foot of the countersink cage contacts the top face of the wedge squarely flush and the countersink pilot aligns with the centerline of the hole pattern Attach a pi...

Page 32: ...me to vary the angle of the rivet gun while driving the rivet Start with the rivet set parallel to the rivet shank and tilt it to set the rivet flush to the skin as the rivet sets Repeat the initial p...

Page 33: ...ween succeeding grips with the seamer On long thin pieces put the sheet on an even edged table with about a 1 4 inch overhang and draw a block of hardwood or plastic along the edge with just enough do...

Page 34: ...tter not a hacksaw The resulting end will be square After making the cut deburr the interior edge of the tube end and polish the end of the tube with fine crocus cloth emery paper or a Scotchbrite whe...

Page 35: ...ep oil from your skin off the surfaces to be sealed and protective cream when sealing the tanks Why expose your skin and lungs if you can prevent it Working with tank sealant can be a messy propositio...

Page 36: ...ctions EXCEPT that we apply the first coat straight out of the can and un reduced using a Bondo squeegee rather than a roller or spray gun Using a squeegee to apply the first coat forces the filler in...

Page 37: ...use a regular twist drill A twist drill tends to fracture the acrylic due to its tip design Using a regular twist or plexi drill to enlarge a pre drilled hole is not recommended and will practically g...

Page 38: ...der a new AN3 bolt and MS21042 3 all metal lock nut Our tests showed an average friction drag torque of 14 in lbs your results may vary The standard torque for this nut bolt combination from the table...

Page 39: ...An example of this would be including the transponder antenna lead or a strobe power lead in the same bundle with the mike wire or headset leads The impulses created by either the transponder or the s...

Page 40: ...which are discussed here and illustrated in Figure 1 For both styles of backshell ensure that the wires are properly installed and heat shrink tubing is installed to secure the wire bundle The two pi...

Page 41: ...r 2 gauge wires are usually not insulated While some barrels are continuous or braised the industrial quality barrel will be a folded or rolled barrel When crimping it is important to note where the s...

Page 42: ...ES 320562 BUTT SPLICE 250 281 TH 450 ES 320571 RING TERMINAL 1 4 203 234 TH 450 ES 320619 RING TERMINAL 6 203 234 TH 450 ES 321045 RING TERMINAL 1 4 203 234 TH 450 ES 323990 RING TERMINAL 10 188 219 T...

Page 43: ...wire grip and insulation grip wings tend to rotate the pin in the tool s dies as they close This can result in a poorly shaped crimp or even broken wings Use a pair of pliers to bend the wings into a...

Page 44: ...size having a nominal pin diameter of 063 Use pockets E and B to install the smaller pins like D subminiature pins found on many instruments and avionics products Some connectors may be supplied with...

Page 45: ...uch as diodes and resistors Such components are shown on the overall electrical schematic available from the downloads page of the Vans Aircraft web site Continuity Test CAUTION Checking the wrong pin...

Page 46: ...t than trying to use a small range of a single turn potentiometer The usable range will always start at the full clockwise end of the potentiometer range A short note on the concept of an audio mixer...

Page 47: ...io system may be transmitted through ground connections to the audio system and most often the music ground lo By removing the music lo connection the music will have no connection to ground and the l...

Page 48: ...em Trim motor does not move or low voltage present at trim motor Solution The trim speed is controlled by a pulsed voltage ie the power is turned on and off quickly the longer it is off the slower the...

Page 49: ...ction are aluminum and steel The aluminum is of various alloys but we can use 200 FPM as a cutting speed for all of them The steel is 4130 chrome molybdenum alloy We can use a cutting speed of 60 FPM...

Page 50: ...ersion are depicted in decimal form with a three decimal place accuracy We realize that most tape measures do not have three decimal place accuracy and so have provided a conversion table to facilitat...

Page 51: ...s specified Manufacturing tolerances for the NAS1149 washers are tighter than are those for the AN960 washers AN Part No AN960 4L AN960 4 AN960 6 AN960 8 AN960 10L AN960 10 AN960 416L AN960 416 AN960...

Page 52: ...is value under the Actual Size OD column and read the corresponding NPT fractional value from the Designated Size column 5 26 continued PAGE REVISION DATE VAN S AIRCRAFT INC PAGE REVISION DATE 09 24 1...

Page 53: ...may not be shown tapered AN823 4D AN822 8D AN816 2D AN816 4D AN816 6 2D AN816 8D AN822 6D AN822 4D AN823 8D AN823 6D 1 8 PIPE PLUG 1 4 PIPE PLUG FIGURE 1 FITTING IDENTIFICATION SEE VAN S CATALOG FOR C...

Page 54: ...tructions provided with a part assembly that is included in the kit wheels and brakes for example should there be an instance where the instructions from Van s contradict the instructions provided wit...

Page 55: ...w B B Match Drill 30 the inboard holes shown in Vew A A Cleco the doublers to the spar SECTION 6 EMPENNAGE RV 8 8A SECTION 6 EMPENNAGE 6 2 REV 13 2 25 14 Drill match drill all the holes inboard of the...

Page 56: ...be primed RIVETING THE HORIZONTAL STABILIZER Locate the rivet holes in the rear spar that will attach the HS 706 HS 708 and HS 00005 ribs and the HS 412PP hinge brackets Put tape over them to prevent...

Page 57: ...V 8 8A SECTION 6 EMPENNAGE 6 6 REV 13 2 25 14 Trim the flange of the stiffener surface perpendicular to the skin to fit inside the tapered rudder Single notches on the edge of the stiffener note the b...

Page 58: ...but it does require careful attention to detail The majority of builder mistakes on the empennage are made on the left elevator and trim tab Fair warning Because of the complication of the trim tab we...

Page 59: ...nterbalance skin to E 703 and E 704 overtop of E 714 The step in the front face of E 714 should butt against the outboard edge of E 713 Use the two holes in the forward face of E 713 as a guide and dr...

Page 60: ...the bend line toward the center of the trim tab Compensate for this by offsetting the bend line approx 1 32 from the desired bend location RV 8 8A SECTION 6 EMPENNAGE 6 12 REV 13 2 25 14 Clamp the inb...

Page 61: ...l The counterbalance arm should align evenly with the stabilizer Secure the elevator in this position Fabricate a drill bushing with an outside diameter of 1 4 and an 3 32 inside diameter Any small me...

Page 62: ...SECTION 6 EMPENNAGE RV 8 8A 6 15 REV 13 2 25 14 RV 8 8A SECTION 6 EMPENNAGE 6 16 REV 13 2 25 14 Figure 6 1 Figure 6 4 Figure 6 2 Figure 6 3...

Page 63: ...SECTION 6 EMPENNAGE RV 8 8A 6 17 REV 13 2 25 14 RV 8 8A SECTION 6 EMPENNAGE 6 18 REV 13 2 25 14 NOTES...

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Page 65: ...oles in the spar to the proper depth for the 8 screw The pilot will center in the countersunk platenut well enough to keep the hole round and concentric Tip cut a 8 screw short so that it enters the K...

Page 66: ...ng jig mounting the wing in a stand will make it easier to build A stand allows access to both sides of the wing and makes it easy to take measurements and assure the wing is straight The wing has no...

Page 67: ...spar and the wing spar The fit between the spar baffle tank RV 8 8A SECTION 7 7 6 8s7 1r11 06 13 11 skin and leading edge should be perfect If not elongate the holes in the baffle inboard or outboard...

Page 68: ...faces Once cured it is difficult to remove CLOSING AND FINISHING THE TANK If you are using a float type fuel sender adjust and check it before closing the tank Dimensions for the float arm of the IE F...

Page 69: ...n gap fairing DWG 13A to the rear spar Drill deburr and dimple where required and rivet the W 724 aileron gap fairing to the rear spar INSTALLING THE PITOT LINE AND WIRES Install the pitot line and fi...

Page 70: ...in the fuselage kit not in the wing kit ATTACHING AILERONS TO THE WING Completely finish the flaps and ailerons before mounting them to the wing RV 8 8A SECTION 7 7 12 8s7 1r11 06 13 11 Set the wing w...

Page 71: ...ith clecoes Remove the clecoes before the resin is fully hardened When cured cleco the W 715 1 tips back on the wing and drill out to full size Remove the tips and machine countersink the fiberglass t...

Page 72: ...e outside of the tank skin Fig 7 12 An interior fuel tank rib riveted and sealed Above Fig 7 13 Details of the inboard bay The access cover with the fuel sender attached will cover the large hole on t...

Page 73: ...g plates are positioned with the large hole nearer to the bottom of the firewall CAUTION In this step do not match drill the 13 holes at each end of the F 801C 1 common to each of the WD 802 L 1 R 1 e...

Page 74: ...N 8 THE FUSELAGE 8 4 8s8PP 1 r1 06 23 11 NOTE Do not dimple countersink the four outboard 30 holes on each end of the crossmember that are also common with the F 802R L 1 R 1 Fuselage Bulkheads DWG 61...

Page 75: ...or Assembly RV 8 8A SECTION 8 THE FUSELAGE 8 6 8s8PP 1 r1 06 23 11 If there is any misalignment Final Drill the large bolt holes in the Fwd Floor Panel using the holes in the WD 813 1 Bolt Weldments a...

Page 76: ...WARD FUSELAGE SUB STRUCTURE This section RV 8A Only Flute the flanges of the F 866B 1 Upper Fwd Baggage Bulkhead and the F 866A 1 Lower Fwd Baggage RV 8 8A SECTION 8 THE FUSELAGE 8 8 8s8PP 1 r1 06 23...

Page 77: ...ents would help the fit of the bolt in the hole Remove the landing gear weldments and using a round file remove material from the landing gear weldment holes in the areas of mismatch Remove material f...

Page 78: ...er Section Bulkhead Assemblies Deburr all holes drilled in the previous step Install the two nutplates on the F 804B 2 Center Section Aft Bulkhead Subassembly top plate that do not rivet through the t...

Page 79: ...826 1 Right Center Bottom Skin and the F 827 1 Left Center Bottom Skin which are common with holes in the Seat Rib Assembly NOTE Do not dimple countersink the fwd and aft most rows of holes that are n...

Page 80: ...RE This section RV 8 Only Add a curve to the top 4 1 2 inches of the F 804H 1 1 Center Section Side Plates to make them closely match the contour of the F 804 Center Section Fwd and Aft Bulkheads See...

Page 81: ...a hand seamer to adjust the bend an gle and then re flute them as necessary so they are straight RV 8 8A SECTION 8 THE FUSELAGE 8 18 8s8PP 1 r1 06 23 11 Move the Fwd Fuselage Sub Structure so that th...

Page 82: ...TE The F 822 1 Fwd Floor Panel is sandwiched between the fwd and aft bottom flanges of the F 804 Center Section Assembly and the F 826 1 F 827 1 Center Bottom Skins See Detail B DWG 67 RV 8 8A SECTION...

Page 83: ...the flanges on the F 812C 1 aft Bulkhead DWG 70 NOTE Identify the F 812A 1 by the 1 8 holes in the side flanges RV 8 Only Mark the vertical position of the WD 409 Tail Spring Mounts top edge on the f...

Page 84: ...SECTION 8 THE FUSELAGE 8 24 8s8PP 1 r1 06 23 11 Cleco the F 818B L 1 Baggage Rib Angle to the F 818 L 1 Baggage Rib as shown in the Baggage Rib Assem bly DWG 71 Final Drill 30 all 1 8 holes common be...

Page 85: ...ons flush to both webs of the WD 802 L 1 R 1 Engine Mount Brackets Clamp each F 848 1 Upper Longeron Gusset tightly against its associate F 887 L 1 or R 1 Upper Longeron Use clamps as needed on the re...

Page 86: ...own in Detail G DWG 71 Cleco the F 812B 1 Angle Control Stop in position on the F 819 1 Aft Deck Cleco the F 811C 1 Angle and F 811D 1 Spacer Control Stop in place on the bottom of the aft deck See De...

Page 87: ...sembly and the Fwd Fuselage Sub Structure NOTE Remove only the skin re cleco all sub structure parts back to their respective locations RV 8A Only Cleco the F 880C L 1 Fwd Seat Ramp Rib to the F 8112...

Page 88: ...Fwd Inboard Seat Rib Assemblies Deburr the corresponding holes in the Fwd Inboard Seat Rib Assemblies Deburr the rivet holes at the fwd and aft ends of F 826 1 and F 827 1 Mid Bottom skins Deburr all...

Page 89: ...age Sub Structure to the Center Section Assembly Cleco the bottom flanges of the center section assembly from the inside Remove the nut from the bottom bolt in each F 814E 1 Seat Ramp Supports and pus...

Page 90: ...1 Doubler Plates in place on the sides of the fuselage DWG 67A RV 8A Only Uncleco and remove the F 871 1 Fwd Baggage Side DWG 63 Add some ballast to the fwd fuselage floor in preparation for adding t...

Page 91: ...y and the two angles Final Drill 40 the 3 32 holes common between the battery tray and the two angles and the 3 32 holes used for attaching the four nutplates to the aft side flange of the battery tra...

Page 92: ...to the F 822 1 Forward Floor Panel RV 8 8A SECTION 8 THE FUSELAGE 8 40 8s8PP 1 r1 06 23 11 Rivet the F 802K 1 L G Forward Crossmember to the F 822 1 Forward Floor DWG 61 Rivet the two nut plates to th...

Page 93: ...gles to the F 890 1 Fwd Floor Panel RV 8 8A SECTION 8 THE FUSELAGE 8 42 8s8PP 1 r1 06 23 11 Rivet the F 896 L 1 R 1 Nose Gear Reinforcement Angles to the F 893 L 1 R 1 Fwd Floor Ribs Place a blob of R...

Page 94: ...in and F 851 L 1 R 1 Forward Bottom Skins See Installing the Bottom Skins DWG 75 RV 8 8A SECTION 8 THE FUSELAGE 8 44 8s8PP 1 r1 06 23 11 Match Drill 1 4 the F 822 1 Forward Floor Panel F 843 L 1 R 1 L...

Page 95: ...r cutting the thin material RV 8 8A SECTION 8 THE FUSELAGE 8 46 8s8PP 1 r1 06 23 11 Deburr the edges of the F 832A 1 Front Seatback Make the F 832E 1 Front Seatback Hinge by cutting to length and dril...

Page 96: ...in Detail D DWG 77 NOTE Position the blocks so that a trimmed corner is at the out RV 8 8A SECTION 8 THE FUSELAGE 8 48 8s8PP 1 r1 06 23 11 board aft corner of each block as installed Temporarily bolt...

Page 97: ...3 32 flush riv ets called out in Seat Floors DWG 77 Only rivet the three F 830B 1 Floor Stiffeners that use 3 32 rivets and only one of the rivets used to attach the F 830F 1 Floor Stiffener is 3 32 N...

Page 98: ...t RV 8 8A SECTION 8 THE FUSELAGE 8 52 8s8PP 1 r1 06 23 11 Remove the F 864E 1 Cable Anchor from the F 864A 1 Throttle Quadrant Mount Deburr the 30 holes in the cable anchor that were drilled in the pr...

Page 99: ...epicted in Throttle Quadrant Assembly DWG 68A NOTE During final assembly the throttle quadrant and the engine control cables must first be installed on the throttle quadrant mount assembly The cables...

Page 100: ...centered between the string lines and that the three rudder hinge points on the vertical stabilizer rear spar are aligned Match Drill 30 the eleven 1 8 holes in the F 884 Attach Plate into the VS 702...

Page 101: ...and WD 412B Rear Control Stick Base RV 8 8A SECTION 8 THE FUSELAGE 8 58 8s8PP 1 r1 06 23 11 Use a file or sander to progressively remove material from the ends of both bronze bushings Remove material...

Page 102: ...le Supports See F 805B 1 Floor Support Angle Detail DWG 69 Final Drill 40 and machine countersink the nutplate attachment rivet holes Rivet the nutplate to each rudder cable support Install the two F...

Page 103: ...on the two brake master cylinders Orient them as shown in Front View DWG 83 RV 8 8A SECTION 8 THE FUSELAGE 8 62 8s8PP 1 r1 06 23 11 Mount the bottoms of the brake master cylinders to the WD 816 Rudde...

Page 104: ...SO View Carbureted Fuel System DWG 82 Final Drill 30 the 3 32 holes common between the fuel RV 8 8A SECTION 8 THE FUSELAGE 8 64 8s8PP 1 r1 06 23 11 filter bracket and the forward floor panel CAUTION D...

Page 105: ...f the F 869 L 1 R 1 Bulkhead Gussets See Detail A DWG 71 If desired tie down ring stowage is available behind the rear seat as shown in Detail A DWG 71 Make two homemade nutplates by welding a 3 8 16...

Page 106: ...FUSELAGE 8 68 8s8PP 1 r1 06 23 11 Deburr and dimple countersink the holes that were final drilled in the previous step in the F 803D L 1 R 1 Clips so they will nest with the common holes in the F 820...

Page 107: ...he Firewall Assembly and F 866B 1 Upper Forward Baggage Bulkhead See Baggage Door Aft View DWG 84 Rivet the F 803D L 1 R 1 Clips to the F 820 1 RV 8 or F 891 1 RV 8A Forward Side Skins See DWG 74 or 7...

Page 108: ...nd insert the hinge pin RV 8 8A SECTION 8 THE FUSELAGE 8 72 8s8PP 1 r1 06 23 11 The pin hole in both F 873M Latch Blocks is drilled at a slight angle to compensate for the taper angle of the fuselage...

Page 109: ...the wing lower inboard skins from the center of each screw hole towards the wing tip Make a mark on each line 3 outboard from the center of the holes When the wings are attached and the F 826 1 and F...

Page 110: ...shrod Attachment DWG 80 Install the flaps on the wings with the hinge pins See DWG 14A RV 8 8A SECTION 8 THE FUSELAGE 8 76 8s8PP 1 r1 06 23 11 Swing the left flap into its up position while inserting...

Page 111: ...02 Wing Upper Inboard Skins and underlying structure and the screw hole in the top flange of the wing spar Use a 40 piloted countersink cutter The 40 pilot in the cut ter will center in the nutplate T...

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Page 113: ...ils should be located so the canopy skirts transition from the lower canopy frame tube to the fuselage side with no gaps Using a 40 bit drill the four forward most holes in each C 803 canopy rail per...

Page 114: ...oxy For initial fitting scraps of aluminum will be easier and can be re placed later with fiberglass epoxy NOTE The canopy skirt is made with epoxy resin and only epoxies should be used when shimming...

Page 115: ...nes with the final layer butted up next to the electrical tape but not over lapping onto it These strips can be laid up all at once there is no need to let each layer cure before applying the next lay...

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Page 117: ...xle It is possible that the heat treating process used to strengthen the gear leg has expanded the axle slightly and the flange will not slip on smoothly A strip of fine crocus cloth briskly worked ar...

Page 118: ...ely four 6 countersunk screws spaced around the perimeter of the intersection fairing Screws may be installed through non structural RV 8 8A SECTION 10 ENGINE MOUNT WHEELS BRAKES AND FAIRINGS 10 4 8 s...

Page 119: ...BRAKES AND FAIRINGS 10 6 8 s10r9 7 11 11 using the molded in scribe lines and the leading edge parting line as reference points Smooth the template over the outside of the fairing and use spring clamp...

Page 120: ...e scale is perpendicular to the wheel when pulling If the scale reading varies significantly from one direction to the other re adjust the axle nut as required After the breakout force is correct dril...

Page 121: ...of fiberglass cloth must be bonded to the inner surface of the aft fairing to make the thickness constant in the two areas where U 808 touches the fairing Use coarse sandpaper to roughen the surface...

Page 122: ...th a match hole in the joggled section Drill for the screw holes shown Make sure the flap is in the fully retracted position Tape the F 872C Flap Fairing to the side of the fuselage and adjust its pos...

Page 123: ...the finished installation nutplates will be installed on small fiber glass pads laid up inside the wheel pant and the fairing will attach with 6 screws and recessed washers Middle right For a smooth...

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Page 125: ...in the engine case at repose no compression load When installing the engine it is necessary to have it suspended from a hoist When the engine is suspended it can be moved into position on the engine...

Page 126: ...he cylinders When the pump is on the lines are pressurized the solenoid is activated by a momentary switch in the cockpit and fuel flows to the cylinders The only known disadvantage is that the primer...

Page 127: ...ven The variety is so large that Van s often very often cannot offer advice on whether a specific model will work in an RV Remember you the builder are ultimately responsible for making sure the engin...

Page 128: ...h which will yield more RPM at a given throttle setting and thus more power particularly for take off and climb Since it will also within limits provide a higher top speed it improves RV AIRCRAFT SECT...

Page 129: ...ng the torque on prop bolts usually requires removing the spinner bowl and cutting safety wire which often deters builders from this important preventative maintenance practice Do not overlook this im...

Page 130: ...sect 11r8 06 24 11 the ads in magazines such as Kitplanes or EAA s Sport Aviation for prop manufacturers Call and discuss your needs with them Don t be afraid to ask for references RV AIRCRAFT SECTION...

Page 131: ...SECTION 11 ENGINE AND PROPELLER INSTALLATION RV AIRCRAFT 11 13 sect 11r8 06 24 11 RV AIRCRAFT SECTION 11 ENGINE AND PROPELLER INSTALLATION 11 14 sect 11r8 06 24 11...

Page 132: ...SECTION 11 ENGINE AND PROPELLER INSTALLATION RV AIRCRAFT 11 15 sect 11r8 06 24 11 RV AIRCRAFT SECTION 11 ENGINE AND PROPELLER INSTALLATION 11 16 sect 11r8 06 24 11...

Page 133: ...SECTION 11 ENGINE AND PROPELLER INSTALLATION RV AIRCRAFT 11 17 sect 11r8 06 24 11 RV AIRCRAFT SECTION 11 ENGINE AND PROPELLER INSTALLATION 11 18 sect 11r8 06 24 11...

Page 134: ...SECTION 11 ENGINE AND PROPELLER INSTALLATION RV AIRCRAFT 11 19 sect 11r8 06 24 11 RV AIRCRAFT SECTION 11 ENGINE AND PROPELLER INSTALLATION 11 20 sect 11r8 06 24 11...

Page 135: ...SECTION 11 ENGINE AND PROPELLER INSTALLATION RV AIRCRAFT 11 21 sect 11r8 06 24 11 RV AIRCRAFT SECTION 11 ENGINE AND PROPELLER INSTALLATION 11 22 sect 11r8 06 24 11...

Page 136: ...SECTION 11 ENGINE AND PROPELLER INSTALLATION RV AIRCRAFT 11 23 sect 11r8 06 24 11 RV AIRCRAFT SECTION 11 ENGINE AND PROPELLER INSTALLATION 11 24 sect 11r8 06 24 11...

Page 137: ...SECTION 11 ENGINE AND PROPELLER INSTALLATION RV AIRCRAFT 11 25 sect 11r8 06 24 11 RV AIRCRAFT SECTION 11 ENGINE AND PROPELLER INSTALLATION 11 26 sect 11r8 06 24 11...

Page 138: ...SECTION 11 ENGINE AND PROPELLER INSTALLATION RV AIRCRAFT 11 27 sect 11r8 06 24 11 RV AIRCRAFT SECTION 11 ENGINE AND PROPELLER INSTALLATION 11 28 sect 11r8 06 24 11...

Page 139: ...er and the control arm and allows the bearing to move freely at various angles without binding Examples A and B show a situation where the rodend bearing housing has worn and slipped off the ball and...

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Page 141: ...engine cooling and cooling drag These consist mainly of inlet and outlet ducts with improved contours for smoother air flow Also important but not shown here is a portion of the baffle near the front...

Page 142: ...at the front sanding filing the flanges and thick areas to get a good fit The spinner opening should be round height the same as the width You may have to sand the flanges slightly shorter on the top...

Page 143: ...filler the filler will dry fast so do not mix too much Use a popsicle stick to fill the larger areas and use a new single edge razor blade as a squeegee to fill smaller voids and pinholes Come back a...

Page 144: ...front of the spinner with a pencil clamped to it and place the pencil point near at the mark on the spinner nose Remove a spark plug from each cylinder so that the prop can be rotated easily and safe...

Page 145: ...lclad aluminum surface with an acid wash DuPont 255S cleaner Martin Senour 6879 Twin Etch etc followed by an application of Alodine and then directly by DuPont Imron Polyurethane paint While a primer...

Page 146: ...SECTION 13 PAINTING RV AIRCRAFT 13 3 sect 13 pub 3 5 01 RV AIRCRAFT SECTION 13 PAINTING 13 4 sect 13 pub 3 5 01...

Page 147: ...SECTION 13 PAINTING RV AIRCRAFT 13 5 sect 13 pub 3 5 01 RV AIRCRAFT SECTION 13 PAINTING 13 6 sect 13 pub 3 5 01...

Page 148: ...SECTION 13 PAINTING RV AIRCRAFT 13 7 sect 13 pub 3 5 01 RV AIRCRAFT SECTION 13 PAINTING 13 8 sect 13 pub 3 5 01...

Page 149: ...SECTION 13 PAINTING RV AIRCRAFT 13 9 sect 13 pub 3 5 01 RV AIRCRAFT SECTION 13 PAINTING 13 10 sect 13 pub 3 5 01...

Page 150: ...SECTION 13 PAINTING RV AIRCRAFT 13 11 sect 13 pub 3 5 01 RV AIRCRAFT SECTION 13 PAINTING 13 12 sect 13 pub 3 5 01...

Page 151: ...SECTION 13 PAINTING RV AIRCRAFT 13 13 sect 13 pub 3 5 01 RV AIRCRAFT SECTION 13 PAINTING 13 14 sect 13 pub 3 5 01...

Page 152: ...SECTION 13 PAINTING RV AIRCRAFT 13 15 sect 13 pub 3 5 01 RV AIRCRAFT SECTION 13 PAINTING 13 16 sect 13 pub 3 5 01...

Page 153: ...SECTION 13 PAINTING RV AIRCRAFT 13 17 sect 13 pub 3 5 01 RV AIRCRAFT SECTION 13 PAINTING 13 18 sect 13 pub 3 5 01 NOTES...

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Page 155: ...of the datum x Forward C G Limit An airplane operating at or near its forward C G limit will have improved stall and spin resistance and improved stall and spin recovery characteristics It will also...

Page 156: ...dition Following the sample calculations is a blank C G form which may be used for calculating the C G for your RV 8 8A Arms for the locations of the standard loads are provided in the sample calculat...

Page 157: ...SHELF 24 00 152 91 3669 84 TOTAL 1598 00 138954 73 CG 86 96 CG OUT OF LIMITS SAMPLE 5 BIG PEOPLE and FORWARD BAGGAGE WEIGHT ARM MOMENT EMPTY AIRCRAFT 1069 00 76 26 81521 94 FWD BAGGAGE 50 00 58 51 29...

Page 158: ...L CG SAMPLE 5 BIG PEOPLE and FORWARD BAGGAGE WEIGHT ARM MOMENT EMPTY AIRCRAFT FWD BAGGAGE 58 51 FUEL 80 00 PILOT 91 78 PASSENGER 119 12 AFT BAGGAGE FLOOR 138 00 AFT BAGGAGE SHELF 152 91 TOTAL CG RV 8...

Page 159: ...inches FUEL 80 00 Inches PILOT 91 78 Inches PASSENGER 119 12 Inches AFT BAGGAGE FLOOR 138 00 Inches AFT BAGGAGE SHELF 152 91 inches EMPTY AIRCRAFT WEIGHT ARM MOMENT RIGHT WHEEL LEFT WHEEL NOSEWHEEL T...

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Page 161: ...SECTION 15 FINAL INSPECTION AND FLIGHT TEST SECTION 15 FINAL INSPECTION AND FLIGHT TEST RV AIRCRAFT 15 2 SEC 15r8 12 23 10 Be sure the linkage and springs on a steerable tailwheel are correctly tensio...

Page 162: ...ests he SECTION 15 FINAL INSPECTION AND FLIGHT TEST RV AIRCRAFT 15 4 SEC 15r8 12 23 10 feels he needs concentrating on testing the airplane rather than the engine An untested engine in an untested air...

Page 163: ...15r8 12 23 10 x The canopy comes open unexpectedly Obviously these are not the only things that can happen without warning on that first test flight however they are probably the most life threatening...

Page 164: ...in time or geogra phy just for the sake of getting more photos or video time Also proximity of formation flight and or maneuvers for photo purposes should not be allowed to compromise safety Keep your...

Page 165: ...e For example your initial flight was probably made with less than full fuel and with a minimum payload But how will the airplane behave with full fuel and at gross weight Will the CG stay within safe...

Page 166: ...attitude At traffic pattern altitude this can be fatal Determine and record how much altitude is ordinarily lost in making a 90 degree gliding turn a 180 degree and a 360 degree turn Make similar chec...

Page 167: ...e Stability and its Adjustments Aircraft stability is rather complex field generally beyond the grasp of the average builder pilot We will attempt to explain a few of the basics to test and what to wa...

Page 168: ...ots of decreasing intensity will occur before the yaw will dampen out An overshoot is an excursion to either side A complete yaw cycle comprises 2 overshoots SECTION 15 FINAL INSPECTION AND FLIGHT TES...

Page 169: ...so within just a mph or two of the fully developed stall The other characteristic being evaluated is a laterally uniform stall or what is often called a straight forward stall Airfoil irregularities...

Page 170: ...N AND FLIGHT TEST RV AIRCRAFT 15 20 SEC 15r8 12 23 10 any leakage can compromise an otherwise accurate system One method of checking a pitot system for leaks is just a clear plastic tube partially fil...

Page 171: ...ove Vne FAA certification criteria require flutter test ing up to Vne plus 10 or about 20 mph The flutter testing performed consisted of exciting the controls by sharply slapping the control stick at...

Page 172: ...64 56 Top end of Green Arc Max structural cruise speed 180 180 193 180 Blue Line Maneuvering speed Max permissible speed at which full control can be applied Speed at which full elevator control woul...

Page 173: ...2 178 5 2 177 35 mph True airspeed from above True Indicated Airspeed 178 5 Approx 1 percent calibration error AIRSPEED CALIBRATION RUN 2 Conditions and Data 1000 MSL 76 deg F 171 IAS 2650 RPM 24 Man...