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RV-7 Construction Log
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Date:  9-15-2013
Number of Hours:  4.10
Manual Reference:  p 8-5
Brief Description:  Aft Fuselage - Deburring, etc.

I started today by looking at what it would take to make a new tab for the one I cracked on the forward half of the F-712 bulkhead yesterday (photo 1). I have a piece of spar web and a scrap rib (both 0.032) from the HR II project both of which already have a nice factory bend radius that I can use. I decided to wait and see if Van's support says I need a shim between the tail spring mount and this bulkhead, and if I do I'll try to incorporate the new tab into that.

I then trimmed the vinyl off the tail cone bottom skin and the aft bottom skin exactly where the side skins overlap so I can prep and prime those faying surfaces, and deburred the outside of those holes.

I spent the rest of this work session on what IMO is one of the most onerous tasks in the build, and that is edge deburring. I got all the way around the tail cone bottom skin, both side skins, and down one side of the aft bottom skin. Photos 2 & 3 show the setups I used to stabilize the side and bottom skins so I could deburr the long edges from a relatively comfortable stance. Both are more stable than they look as there are a couple of jugs of clecos behind them. I started out using a 2" scotchbrite wheel, but that makes the edges a bit wavy. No problem on the underlying edges, but I want as straight an edge as possible for overlying edges, so I switched to a flat needle file and maroon scotchbrite, which really isn't much slower, and leaves a MUCH nicer finish. Also, it looked like I’d have problems using the wheel on the J-channels and the long J-edges of the bottom skin.
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Cracked tab in the forward half of the 712 bulkhead that will need to be replaced

Cracked tab in the forward half of the 712 bulkhead that will need to be replaced

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My setup to stabilize an aft side skin for deburring the top edge.

My setup to stabilize an aft side skin for deburring the top edge.

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My setup to stabilize the aft bottom skin for edge deburring.

My setup to stabilize the aft bottom skin for edge deburring.

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