My RV–10 X Aircraft Build

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I am moving this "Blog" of building the X-10 to a new web site, called KITLOG Pro V2.0.   Van’s offered this software for sale at a price of $49.00 dollars and because I would like a nice album of what I am doing for the FAA, DAR, future potential buyer and myself I am switching to KIT LOG Pro V2.0 that offers a very nice .pdf print out of such items as, building log, expense log, weights and balances, etc… of the step by step process of building the X-10 in relationship to the Van’s kit plan set.  There are also about 591 Builders of others X-Aircraft project "uploads", that you might find very interesting.

 My New Web Site is =>   http://www.mykitlog.com/conrad

 Other Builders Web site is =>  http://www.mykitlog.com/search.php

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The Wings are Completed ~ 400 hours or 8 Months of Off_On Work

the Completed Wings w/out the Flaps are both in the Shed

Right Wing with Wing Tip Fairing Light

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June 19th, 2009……. I am declaring the X_10 WINGS COMPLETED, except for final paint, and it’s time to get prepared for the delivery of the next sub-kit, the FUSELAGE sometime around the 4th of July, 2009.  Total time for the WING kit was about from November 15th to June 19th (~ 8 months ) and right around 400 hours that will include painting with primer/finisher. Overall the X-10 WING building was actully FUN, with the exception of riveting a few places that were hard to reach on the wing skins, overall the assigned tasks were not very difficult. No real advice for other builders except just keep to your schedual and before you know-it the WING kit will be complete.

Total time to date => 739 hours or 13 months of hobby work……….

6/10/2009 … Section OP36-3 … Steps 1 to 10 … I completed the light kit for the X-10.  Beginning with WING TIP NUT PLATE INSTALLATION step 1 to 3 by attaching the nut plates as shown on page 36-3 figure 1.  Then I created the halogen light fixture VA-194C MR16 Cup as shown in figure 2. I then primed the parts with DTS primer and ass the LANDING LIGHT SUBASSEMBLY as in figure 3.  Finally attached the completed subassembly  LC-EYF MR16 75 Watt Narrow Beam Bulb (both left and right ) to the LC MR16 2 pin Disk socket as shown in figure 4 LANDING LIGHT SUBASSEMBLY INSTALLATION and attached to  the W-1015-L/R Wing Tip assembly.  Time about 3 hours for both Left and Right Landing Light.

Landing Lights Test Fit into the Wing Tips

Van’s, Leading Edge and NAV Lights Power Connection Strip

6/09/2009 … Section OP36-2 … Steps 1 to 9 … TRIMMING THE MR16 CUP, step 1 placed the VA-194B over the VA-194C and traced an outline an then removed the “hatched” area as shown in figure 1.  CUTTING THE COMPRESSION SPRING, Step 2 I and two compression spring by cutting 1 .26X2.9 springs as shown in figure 2. MAKING THE MOUNT TUBES, step 3 I fabricated six Mount Tubes from AT6-058X5/16 aluminum tubing.  Step 3 PREPARING THE WING TIP for cutting. I centered the W-1032 Landing Light Base Plate on the face of the Wing Tip as shown in figure 4 and Match Drilled using a #27 drill the holes as shown and then machine counter sunk the appropriate holes for K100-06 Nut plates for the match drilled #40 holes and rivet with AN426AD3 flush rivets. Step 9 following the dimensions as show in figure 4 I measured and marked the area appropriately and then removed the shown  hatched area with a Uni-Bit drill and then a hacksaw. After obtaining a rough fit opening I used a grinder and a sander to smooth-up the rough edges. Time about  3 hours for both Left and Right Wing Tips.  

Halogen 75 watt Wing Tip Land ing Light Assembled

Leading Edge 75watt halogen light from Team Rocket

6/7/2009  Section  Page 24-3 Step 5 to 7. LAYING OUT THE WING TIP AFT RIVET PATTERN, step 5, I inserted the W-10016 Wing Tip Rib into the aft position  roughly 2/3/8 inch from the aft end of the Wing Tip, as shown in Figure 3 Wing TIP RIB ISO View. Marked the Wing  Tip at 5/16 inch for drilling #40 holes every 1.5 inches started drilling holes. Machine countersunk the #40 holes just drilled in the Wing Tip to accept the head of AN426AD3-4 rivets. Removed the Wing Tip Rib and removed the alodine coating and primed the reinserted into the Wing Tip assembly and riveted in place.  Time for both Left and Right Wing Tips about 2 hours.

Both Wing Tips Cut-out for the Installation for the Landing Lights

Lens is Fitted Correctly

6/6/2009 … Section 24 Page 24-3 Steps 1 to 4. NUTPLATE ATTACHMENT, Step 1 I Match Drilled #40 then clecoed as I when the Wing Tip attachment holes to the existing holes in the W-1001 Leading Edge Wing Skins, W-1003- Top Outboard Wing Skins and W-1005 Bottom Wing Skins.  Now final drill all the #40 Wing holes to #28. Place a #6 screw into the Wing Tips and screw into the nutplates K1000-06 as seen in Figure 1.  Step 4, Drill #40 holes into each nutplate to attach AN426Ad3-4 rivets, and after deburring machine countersink the #40 and the #6 screw holes. Also using a #6 dimple die you must dimple the Wing Skins to receive a #6 screw.  Time about 4 hours for both wings.

Installing the Nut Plates

6/5/2009 .. Wing Tips Section 24, Page 24-2, Steps 1 to 6. WING TIP TOP and Bottom TRIM, Step 1, I trimmed the edge of the Wing Tip W-1015-L using air rotary cutting saw the edge of the fiberglass at meeting location W-1015-L  and Top and Bottom Aluminum Wing Skins W-1003 to ½ inches.  Then checked for fit and trimmed as necessary again.  Then trimmed the area where the Aileron meets the Wing Tip to just 3/16 inch. Also I checked the work when the Aileron was activated to its full position.   LENS MODIFICATION, Steps, 3 to 5.  The plan is incorrect in how to cut  and install the Lens. I called Van’s technical assistance and asked them to clarify as the kit supplied a different VA-193-L . But after talking to Van’s  I discovered that I was supplied with a newer, simpler to install and better VA-193-L part.  I placed and then taped  the Lens over the Wing Tip light recess area and trimmed with a set of “snipers” to 1/8 inch and then filled to obtain a perfect fit.    Step 5,  I #40 drilled the VA-193-L left Lens at the Upper and Lower recessed corners at 5/16 inches, see Figure 5. LENS INSTALL. Step 6, I match drilled #40 the Nut Plate attachment pattern into the corner recesses to attach the Lens with a #6 screw. I counter sunk the top of the Lens for #6 screws. Step 7 Install the hardware as shown in figure 5. Time about 8 hours for both left and right Wing Tips.

Checking the Fit between the Wing Slins and Wing Tip Faring

Trimmed the Wing Tip Faring to obtain the 3/16 inch gap between the Aileron and Wing Faring

6/3/2009 …Section 23-5, Steps 1 to 4. Step 1,  FORWARD TORQUE TUBE SUB-ASSEMBLY, I inserted the VA-162 Push Rod End into the Long end of the two WD-1014 Aileron Torque Tubes and then Match Drilled with a #30 drill the holes, removed the Push Rod Ends and deburred the holes. Step 2, AFT TORQUE TUBE SUBASSEMBLY, this is a repeat to step 1 but insert the VA-162 Push Rod Ends into the SHORT ends of the Aileron Torque Tubes.   Step 4, MATCH DRILL TORQUE TUBE COLLAR, I inserted the previously made  WD-1014 FORWARD Torque Tube Sub-assembly to the Torque Tube Collars WD-1014C  by only 1 -1 /2 inches as shown in figure 3.  Then I Match drilled the toque tube collar using the holes of the torque tub sub-assembly using a #30 drill. I then Final drilled the holes with a number 12 drill bit. Step 4, TORQUE TUBE COLLAR BOLT INSTALLATION,  I deburred all the #12 holes in order to prepare  for the installation of  four AN3-13A bolts, AN960-10 washers and AN365-1032 lock nuts.  Then I primed with DTS primer all of the sub-assemblies including the insides.  Total Time about 4 hours.

Primed Torque Tubes, Push Rods and BellCrank Tubes

6/2/2009 … Section 23-5 Step 1 and 2. AILERON BELL CRANK BUSHING INSTALLATION, Step 1,  I Deburred the brass bushing BR-065 X .375 X 2.781 Aileron Bellcrank Bushing  and trimmed to the exact length of 2 and 3/ 4 inch and then filed the inside of the WD-421 Aileron Bellcrank to accept   the Brash Bushing. Then as explained in the instructions I at first filed and then reamed with a 1 /4 inch drill bit the inside of the Brash Bushing to accept an AN4 bolt. Step 2, AILERON BELL CRANK INSTALLATION. I installed the WD-421-L/R Aileron Bellcrank with Brash Bush sub-assembly into the left wing assembly as described in figure 2. And tighten the AN4-32A bolt to 70 inch/pounds. Time for both wings about 2 hours.

6/01/2009 … Section 23-3 Steps 4 and 5…. ROD END BEARING AND JAM NUT INSTALLATION, I installed the Jam Nut AN316-4 onto the F3414M Rod End Bearing and then screwed the assembly on to the Threaded Rod Bearing AN490-HT8P for both W-1018A rod assemblies. Step 5, AILERON BELL CRANK SPACER FABRICATION, I created two SPACERS by cutting a stock piece of aluminum AT6-058 X 5/16 inch to the exact length of 1 and 1/16 inch. Time about 1 hour for both Flaps.