JANUARY (38 hours)
RV-6 CONSTRUCTION LOG
| 01 | Deburred and primed Rudder and Rt Elevator skeleton parts. |
5 | |
| 02 | Cut R-410 to shape, rivetted Rudder skeleton together, squeeze-rivetted
rudder skeleton to skin. |
9 | |
| 03 | Completed rivetting of rudder skeleton to skin, rolled rudder LE to shape. | 3 | |
| 04 | Completed rudder. Repaired elongated holes in Rt Elevator skin. Cut L Elevator stiffeners and drilled to skin. | 9 | |
| 07 | Primed inside R Elevator skin and stiffeners. | 3 | |
| 08 | Rivetted stiffeners to R Elevator skin. Drilled L Elevator ribs and reinforcement plates to spar. | 4 | |
| 09 | Drilled and dimpled E-613 to R Elevator tip ribs. | 1 | |
| 30 | Received and inventoried Wing kit. |
2 | |
| 31 | Stored wing kit items in garage. | 2 |
| 01 | Squeezed Rt elev TE to shape. Drilled & rivetted Rt elev skin to
skeleton. 
Removed Left elev horn from Rt elev. Drilled lightening holes in aileron
spars. cut aileron counterbalance to length, drilled Left aileron skeleton
parts. Drilled and dimpled trim tab lower skin to spar and control horn.
Folded end tabs of trim tab.  |
14 | |
| 02 | Deburred and prepared for priming left aileron skeleton parts, trim tab parts, left elevator parts. | 5 | |
| 04 | Drilled stiffeners to Left aileron skin. Deburred, dimpled stiffeners and skin. Prepared stiffeners for priming. | 3 | |
| 13 | Primed Left aileron and elevator skeletons, trim tab, and left elevator skin and stiffeners. | 3 | |
| 17 | Visit by Les Rogers. Rivetted stiffeners to left elevator skin. | 2 | |
| 18 | Rivetted E-615 to left elevator skin. Rivetted spar to lower trim tab
skin. Rivetted ribs, horn, and reinforcements to left elevator spar. Squeezed
trim tab and left elevator TEs.  |
3 | |
| 19 | Completed L elevator skeleton. 
Drilled skin to skeleton, deburred, dimpled. Folded tabs on L elevator
skin.  |
5 | |
| 20 | Assembled L aileron skeleton.  |
1 | |
| 22 | Primed L aileron stiffeners and skin. | 2 | |
| 23 | Rivetted stiffeners to L aileron skin, squeezed TE, drilled to skeleton,
deburred, dimpled.  |
5 | |
| 24 | Rivetted L aileron top skin to skeleton. Drilled, deburred dimpled stiffeners to R aileron skin. | 5 | |
| 25 | Deburred R aileron skin and stiffener edges | 1 | |
| 27 | Deburred lightening holes in R aileron spar. | 1 | |
| 28 | Primed R aileron spar, skin, and counterbalance, L aileron skin, L elevator tip skin. | 2 |
| 01 | Rivetted stiffeners to R aileron skin. Completed L evelator skin dimpling,
and rivetted skin to skeleton. Completed trim tab.  |
8 | |
| 02 | Rivetted trim tab hinge to L elevator. Started rolling L elevator LE. | 2 | |
| 03 | Completed elevator LE. | 1 | |
| 05 | Drilled out pop rivets in L aileron.
Ordered tools from Avery. Ordered new aileron and R elevator parts. |
US$128.00
US$203 |
1 |
| 17 | Disassembled R Wing spar components, Marked taper on W-606C spar reinforcements.  |
2 | |
| 19 | Disassembled L Wing spar components | 1 | |
| 22 | Cut tapers on all 4 W-606C spar reinforcements. 
Purchased tools |
NZ$25.00 | 3 |
| 23 | Filed W-606C tapers. | 3 | |
| 27 | Deburred spar stiffeners | 3 |
| 03 | Deburred spar stiffeners | 2 | |
| 07 | Primed 4 spar stiffeners.
Purchased Port-Etch and PA-10 primer. |
NZ$180.00 | 3 |
| 12 | Prepared and Port-Etch primed 4 spar stiffeners | 5 | |
| 13 | Prepared & primed W-606B spar doublers, 7 stiffeners | 8 | |
| 14 | Prepared last 3 spar stiffeners, made spar spreader angles, touched up previously primed stiffeners. | 5 | |
| 15 | Deburred holes on rear side of main spars W-606A. | 1 | |
| 17 | Dimpled holes in W-606B doublers. Marked tiedown brackets and spreader angles for drilling. | 3 | |
| 21 | Primed last 3 spar stiffeners. | 1 | |
| 22 | Drilled spreader angles to spar, countersunk spreader bars.  |
3 | |
| 23 | Drilled Tie-down brackets to spar. | 4 | |
| 24 | Primed spreader angles, tie-down brackets, deburred L spar W-606A. | 4 | |
| 25 | Primed main spars W-606A, assembled and rivetted R spar (1/8" rivets),
assembled L spar for rivetting (1/8" rivets)   |
8 | |
| 27 | Bolted R spar together.  |
3 | |
| 28 | Drilled through tight rivet holes R spar, disassembled, deburred, reassembled.   |
4 | |
| 30 | Marked out and cut rear spar doublers W-607E & F. Deburred and rounded W-607B & C. | 2 |
| 02 | Marked rivet holes on W-607B & C, marked out one W-607D. | 2 | |
| 03 | Cut out W-607Ds and FL-607B??s from 1/8" plate with jigsaw. Practised driving 3/16" rivets -- rivet gun & 3lb hammer. | 3 | |
| 04 | Practised 3/16" rivets with sledghammer. Cut to length, rounded, remarked,drilled W607B&Cs. Marked & cut W607As. | 4 | |
| 05 | Drilled and deburred stiffeners and doublers to rear spar web. | 4 | |
| 06 | Primed and rivetted rear spars together. 
Separated ribs. |
5 | |
| 07 | Squared up rib flanges. | 4 | |
| 12 | Practised driving 3/16" rivets. | 1 | |
| 17 | Deburred R Wing ribs | 4 | |
| 18 | Drove 20 3/16" rivets. Cut rib reinforcement angles.Made fluting templates.
Fluted R Wing ribs.  |
8 | |
| 19 | Drilled rib reinforcement angles, drilled ribs R9-R14 for spar attach rivets. Cut rib 9 for bellcrank. | 7 | |
| 20 | Cut and drilled 1/16" angle bellcrank mounts, deburred some L Wing Ribs | 3 | |
| 21 | Cut and drilled 1/8" angle bellcrank mounts, deburred 2 more L Wing Ribs. | 3 | |
| 22 | Deburred remaining L Wing main ribs, Fluted L Wing main ribs. | 4 | |
| 23 | Tapered bellcrank mounts, deburred remaining rib reinforcement angles. | 2 | |
| 24 | Primed bellcrank mount parts. | 2 | |
| 25 | Primed R wing LE and main ribs, reinforcement angles.  |
7 | |
| 26 | Built aileron bellcrank mounts on ribs.  |
2 | |
| 27 | Deburred L wing ribs | 2 | |
| 29 | Deburred ribs | 2 |
| 05 | Deburred ribs. | 4 | |
| 06 | Scotchbrited ribs for priming. | 3 | |
| 07 | Primed all remaining ribs, W417As. | 6 | |
| 08 | Deburred remaining tank ribs. Drilled & deburred most holes in
tank ribs. Made bellcrank spacers, drilled bellcrank parts.  |
7 | |
| 10 | Drilled & deburred 7/16" holes in tank ribs. Marked lightening hole positions in flap spars & braces. Marked flange centrelines on flap spars & ribs. | 3 | |
| 11 | Pilot-drilled lightening holes. Drilled flap spars to bottom skins. 
Drilled L hinge to spar. Squared L rib flanges, adjusted L spar flange. |
3 | |
| 13 | Drilled R hinge to flap spar, drilled ribs to spars and bottom skins. | 3 | |
| 14 | Countersunk flap spars, built L FL-606 parts, dimpled bottom skins, ribs. | 7 | |
| 15 | Made flap jig, drilled L top skin, dimpled skins, ribs, spar.  |
7 | |
| 16 | Cut R FL-606 parts. Deburred edges of L flap parts. | 2 | |
| 18 | Completed rivetting of R wing spar with Bob McCready.
Built R FL-606 parts.  |
2
3 |
|
| 19 | Fitted rudder bottom fairing. | 3 | |
| 21 | Received replacement aileron and elevator skins.
Drilled off heads of 10 bad rivets in R wing spar. |
1 | |
| 24 | Drilled stiffeners to L aileron skin, deburred, dimpled. | 3 | |
| 25 | Primed L aileron skin and stiffeners, L flap parts. | 4 | |
| 28 | SAANZ Manawatu chapter meeting here.
Drilled and punched bad rivets out of R wing spar. Rivetted inner ribs to L flap bottom skin. Bought tools. |
$210 | 3
2 2 |
| 29 | Completed assembly of L flap. Drilled R flap top skin to spar and ribs. | 7 | |
| 30 | Drilled R flap top skin to bottom skin | 1 |
| 01 | Deburred and dimpled rivet holes in L flap ribs and skins. | 3 | |
| 03 | Prepared L flap parts for priming | 2 | |
| 05 | Primed L flap parts
Bolted L main spar Bought paint and hardware |
$140 | 2
1 |
| 06 | Completed L flap | 3 | |
| 14 | Received RST Audio panel kit. Mounted diodes and resistors.  |
US$292 | 4 |
| 15 | Completed audio panel assembly, except for plugs. 
Bought tools |
$48 | 10 |
| 16 | Completed audio panel assembly | 2 | |
| 19 | Testing of Audio Panel | 1 | |
| 22 | Completed testing of audio panel | 2 |
| 09 | Final drilled, deburred, reassembled L spar | 4 | |
| 16 | Rivetted stiffeners to aileron skin
Cut elevator stiffeners, drilled to skin, deburred, drilled elevator spar to skin. Vans supplied 3/4x3/4x.032 for stiffeners instead of 5/8x5/8x.025 -- this was used for the outermost 4 stiffeners. |
1
6 |
|
| 17 | Squared rib flanges. Dimpled elevator skin, drilled, deburred ribs to spar & tip skin. Measured, drilled, deburred E-410 and E-411 reinforcements to spar. | 6 |
| 05 | Deburred, Primed R elevator skin, stiffeners, skeleton parts, outside trim tab, L elevator. | 5 | |
| 06 | Rivetted stiffeners to R elevator skin. Built R elevator skeleton.
Cut rivets to length for wing spars |
4
1 |
|
| 07 | Squeezed TE of both ailerons.
Squeezed TE of R elevator. Set up elevator jig, drilled elevator skin to skeleton, deburred, dimpled. |
1
5 |
|
| 08 | Rivetted R elevator skin to skeleton. | 2 | |
| 09 | Deburred lightening holes in aileron spar | 1 | |
| 10 | Drilled ribs to aileron spars, deburred ribs. | 2 | |
| 11 | Primed R elevator bottom, aileron spar and ribs | 2 | |
| 12 | Rolled elevator LE | 1 | |
| 13 | Finished elevator LE | 1 | |
| 14 | Fitted rod-end bearings to elevators, rudder. Test mounted rudder and
elevators.  |
1 | |
| 15 | Prepared empennage parts for priming | 3 | |
| 16 | Primed VS, rudder, elevators | 1 | |
| 17 | Hung rudder. 
Set up for wing spar rivetting Built aileron skeletons |
1
1 3 |
|
| 18 | Completed wing spar rivetting with Bob McCready |
$100 | 2 |
| 20 | Prepare wing spars for final prime
Drilled & re-rivetted L aileron main ribs, drilled nose ribs for aileron skeletons |
1
3 |
|
| 21 | Drilled aileron counterbalances.
Drill L elevator counterbalance reinforcements, Hung elevators, fitting tips.  |
1
3 |
|
| 22 | Hanging elevators, fitting tips.  |
4 | |
| 23 | Fit VS tip
Drill rudder cable holes, countersink and deburr F-604 part holes |
1
3 |
|
| 24 | Deburr F-604 part edges | 2 | |
| 25 | Prime aileron skeleton parts, F-604 parts, HS outside, wing spars | 4 | |
| 26 | Assemble aileron skeletons
Rivet F604A/C |
2
1 |
|
| 27 | Complete rivetting of F604A/C.
Drill L aileron skin to skeleton |
1
3 |
|
| 28 | Complete assembly of L aileron, drill R aileron skin to skeleton | 5 | |
| 29 | Set up workshop in garage
Drill rib reinforcement angles and ribs 1-8 to L spar.  |
4
4 |
|
| 30 | Rivet angles to ribs 1-8, drill ribs A, 11, 12 to spar | 4 |
| 01 | Moving workshop to garage | 5 | |
| 02 | Setting up wing jig | $32 | 7 |
| 03 | Setting up wing jig Cross-arms, wiring garage lights | 5 | |
| 06 | Setting up Cross-arm braces | 2 | |
| 11 | Completed setting Cross-arms. 
Drilled ribs 9-12 to L main spar |
$15.00 | 3
2 |
| 12 | Drilled ribs 13,14 to L main spar. Drilled ribs 1-2 to R main spar.  |
4 | |
| 13 | Cleaned out spare room | 1 | |
| 15 | Drilled ribs 3-7 to R main spar, rivetted on reinforcements. | 3 | |
| 18 | Drilled remaining ribs to R main spar and to R rear spar, deburred, dimpled. | 5 | |
| 19 | Relaid carpet in spare room | 3 | |
| 21 | Attached ribs 3-4 to R main spar. | 1 | |
| 22 | Finished relaying carpet
Attached ribs 1, 2, 5, 6,7 to R main spar. Clecoed rear spar to ribs |
$35 | 2
2 |
| 23 | Attached rib 8 to R main spar, attached ribs 1-9 to R rear spar. | 3 | |
| 29 | Attached ribs 10-14 to R rear spar | 1 | |
| 31 | Drilled ribs to L rear spar.  |
4 |
| 01 | Drilled ribs 5-14 to L rear spar. 
Levelled R main spar in jig.  |
$2.00 | 4 |
| 02 | Investigated repair of R aileron. | 1 | |
| 03 | Attached lower cross-arms to jig posts.
Drilled R outer bottom skin to skeleton.  |
$18.50 | 4 |
| 05 | Drilled R inboard bottom skin to skeleton and W-625 half-rib, mounted
bottom W-425 bellcrank gusset.  |
4 | |
| 06 | Drilled R outboard top skin, half of R inboard top skin to skeleton. | 4 | |
| 07 | Completed drilling skins to R skeleton. Drilled doubler to R skeleton/skin. Mounted top bellcrank gusset. Deburred half of R skeleton. | 5 | |
| 08 | Completed deburring R skeleton, deburred outer skins. Made access covers, drilled R access cover to skin/skeleton. | 5 | |
| 10 | Drilled inner wingwalk holes #30, dimpled bottom of skeleton, deburred inner skins and wingwalk, dimpled some of bottom skins. | 4 | |
| 11 | Completed dimpling of bottom skins. Dimpled inboard upper skin. Drilled and rivetted bellcrank mounts to ribs. | 3 | |
| 12 | Dimpled doubler and inboard top of skeleton. | 1 | |
| 18 | Dimpled and countersunk remainder of R skeleton. Clecoed ribs to L skeleton. | 1 | |
| 19 | Attached ribs 3-8 to L main spar. Dimpled R outboard upper skin. | 3 | |
| 26 | Attached ribs 1-2 to L wing spars. Levelled and plumbed L wing skeleton. | 3 | |
| 27 | Drilled outboard lower skin to L skeleton.  |
2 |
| 01 | Drilled half of bottom inboard skin to L skeleton. |
2 | |
| 04 | Completed drilling bottom inboard skin to L skeleton. | 1 | |
| 09 | Drilled bellcrank gusset and half rib to bottom skin. Drilled top outboard skin to spar. | 2 | |
| 13 | Completed drilling skins to L skeleton. | 4 | |
| 14 | Deburred skins. Dimpled some skins | 5 | |
| 15 | Completed dimpling skins. Deburred half of skeleton. | 2 | |
| 16 | Completed skeleton deburring. Dimpled skeleton. | 2 | |
| 17 | Deburred gussets and skin edges. | 2 | |
| 21 | Deburred and rolled skin edges. Countersunk skeleton. Bevelled skin overlap. Drilled nutplates for bellcrank cover to L skeleton and skin. Prepared skins, gussets, covers for priming. Countersunk nutplates. | 7 | |
| 22 | Primed doublers, covers, gussets, nutplates, insides of all main skins. |
3 |