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RV-7 Construction Log
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Date:  2-15-2012
Number of Hours:  1.80
Manual Reference:  pp 6-9, 6-10
Brief Description:  Countersinking Elevator Parts

I countersunk both E-702 elevator spars where they attach to their respective root ribs. The countersink cage wouldn't fit close enough to the spar to get the top and bottom holes, so I set up my drill press with the counter sink in the speed handle extension. (See Photo 1). I had to go slow and after 4 or 5 iterations the rivets fit nice and flush.

Next, I countersunk the top flange of the E-606PP trim spar. I was going to clamp it to the table edge and drill to the table for pilot holes, but the spar was just a bit too narrow. Instead, I clamped a piece of 1/4" plywood to the table and match drilled pilot holes in that. Came out great.

Next, I countersunk the E-714 counterweights to fit the #10 dimples in the E-713 counterweight skins. I tested the setup in some 0.125 scrap I had, and noticed that the dimple die and countersink make slightly different angles. Even when the countersink in the scrap part was at least 0.010 deeper than the dimple was tall, the surface around the dimple wouldn't lay flat in the countersink. I set the depth for a #10 screw plus about 0.030 and called it good.

In this part of the instructions, I was also supposed to countersink either the E-606PP trim spar or the E-705 root rib for -3 flush rivets, but noticed I had already drilled out the holes to #30 (like most every other rib-to-spar hole so far). I'm thinking #4 universal head rivets will be OK, as the instructions said the flush head of the specified rivet could be on either side of the joint. I'm thinking the ideal rivet here would be a -3 universal head, but they would be the only two in the empennage. I'll post a question on VAF and email Van's support to be sure.
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Countersinking close to the E-702 Spar Flanges with the Drill Press.

Countersinking close to the E-702 Spar Flanges with the Drill Press.

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My setup for countersinking the top flange of the E-606PP trim spar.

My setup for countersinking the top flange of the E-606PP trim spar.

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E-714 counterweights countersunk for #10 screw dimples.

E-714 counterweights countersunk for #10 screw dimples.

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