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RV-7 Construction Log
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Date:  9-16-2012
Number of Hours:  6.20
Manual Reference:  
Brief Description:  Left Wing Leading Edge and Tank

When I first got into the shop this morning, the tank was still on the wing and cool enough from the night before that the balloon I'd sealed to the vent was sucked in on itself... a good sign. After I match drilled the screw holes for the tank to leading edge joint and removed the tank for access to the joint plate, I put the tank on the workbench close to the garage door where the heat of the day could get to it, I noticed the balloon inflated enough to hold its own weight. More good news! The sealant on the balloon was still sticky and I wanted to give it as much time as I could to cure, soI went ahead and finished the joint plate nutplates, final riveted the W-408 rib, dimpled all the tank screw holes, final drilled the leading edge ribs to the spar and deburred the holes, and clecoed the leading edge to the spar (for the last time!) before testing the tank.

Toward late afternoon, I pressurized the tank with my in-line pressure regulator set as low as I could and still get flow (about 5 psi). It took a half minute or so to get enough air in the tank, but the balloon finally inflated, and I did the soapy water test. I got through all the skin and baffle rivets, then turned the tank on end to test the end ribs. Unfortuately, I was so engrossed in the test that without thinking I turned the tank up on the inboard end and popped the balloon (DUH!!). Fortunately, the remnants of the balloon sealed itself over the short tube I'd sealed it to, and the tank still held pressure, so I was able to go ahead and test the end ribs. The only leak at all was some very small bubbles from the schrader valve where it was threaded into the drain fitting. A couple of flats of tightening fixed that. As far as I can tell, this is a leak-free tank, but I may still do the manometer test for an extra warm fuzzy.

Rivets today: 57
Rivets Total: 3684
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A few minutes in the light of day inflated the balloon.

A few minutes in the light of day inflated the balloon.

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Match drilling nutplates on the W-423 joint plate.

Match drilling nutplates on the W-423 joint plate.

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Note standing soapy water. No bubbles from the infamous aft corners.

Note standing soapy water. No bubbles from the infamous aft corners.

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