Vans Aircraft RV-12 Build, Section 22: FWD Lower Fuselage (part 4)

Reference: page 22-04, 22-05; 2 hours

I have passed the 1,000 picture mark during the construction of this RV-12. This has created a challenge as I am currently storing the pictures on Picasa. Not a real problem as I just needed to set up a new file folder, however the day is coming when I will run out of room on Picasa. But that day is ot today so let's get to it!

Note: The fuel flow meter provided will be one of two types. Page 28-05 of the RV-12 plans depict both types. Determine the fuel flow meter provided with the kit and use the applicable hardware.

Builder's note: My kit came with the FT-60 Fuel Flow Meter so that is what the mount below is built to match. Some of the steps out of sequence as can be seen by the primer shown in the pictures.

Step 1: Install nutplates to the VA-188 FLO_SCAN Mount Bracket per the call-outs in Figure 1 if using a Flo-Scan Fuel Meter or Figure 2 is using a FT-60 Fuel Flow Meter. These figures are on page 22-04 of the RV-12 plan by Van's Aircraft.



Step 2: Cleco the FLO-SCAN Mount Bracket to the Fwd Fuse Floor Skin. Final-Drill #30 the four attach holes. Remove the bracket and deburr both parts.



Step 3: Rivet the FLO_SCAN Mount Bracket to the Fwd Fuse Floor Skin per the call-outs in Figure 2 on page 22-04 of the RV-12 plans. Manufactured Head on the Bottom of Fuselage



This completes page 22-04.

Reference page 22-05.

Caution: Do not rivet the upper row of holes in the F-1271-L & -R Fwd Fuse Corner Skins that will later attach to the F-1270-L & -R Fuselage Side Skins

Step 1: Cleco then rivet the Forward Lower Fuse Assembly to the Mid Fuse and Bottom Skin Assembly as shown in Figure 1 & 2 of the RV-12 plans on page 22-05. The skins from the Fwd Lower Fuse lie over outside of the skins on the Mid Fuse and Bottom Assembly.



In the picture below I'm not saying "the RV-12 is number one", which of course is a given. But rather I found by starting with the bottom rivet and working upwards made the riveting job much easier.











This completes both page 22-05 and section 22 of the RV-12 airplane.

Vans Aircraft RV-12 Build, Section 22: FWD Lower Fuselage (part 3)

Reference: page 22-03, 5 hours

This post deals with more work on the RV-12 lower firewall and with the "fun" of fuel tank sealant. It isn't that bad just messy and be glad we don't have to drive solid rivet coated with fuel tank sealant for the RV-12. So here are the tips I use when using fuel sealant:

1. Wear old cloths.
2. Wear gloves and safety glasses.
3. Have a set of "proSeal" clecos.
4. Pre-plan each job.
5. I use an old electronic scale to measure both components.
6. Use a zip-lock bag or syringe (depending on job size) to squirt the mixed fuel tank sealant where I need it.
7. New Popsicle sticks and tongue depressors come in handy.
8. Clean up as needed with Acetone or MEK.
9. Remember the sealant get everywhere no matter how careful you are, so learn to roll with it.
10. It will remain soft and "flow" for a lot long than you think it should.
11. Store in a cool to cold place (not the freezer) as this helps extend the shelf life of the unmixed components.


Step 1: Cut apart and deburr the F-1257 Rudder Pedla Supports Channels.



Step 2: Dimple the aft two holes and nutplate attach holes in the F-1257 Rudder Support Channels. Dimple the corresponding holes in the F-1201B Firewall Shelf.

Builder's note: I modified an old die so as not to damage the flange of the Rudder Support Channel.
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Step 3: Dimple then rivet nutplates to the F-1201B Firewall Shelf and F-1257 Rudder Channels as shown in Figure 2 of the RV-12 aircraft planes on page 22-03.





Step 4: Smear a thin layer of fuel sealant on the top surface of the top flange of the F-1201C Firewall Bottom. Cleco then rivet the Firewall Shelf and Rudder Pedal Support Channels to the Fwd Lwr Fuse Assembly per the call outs in Figure 2 on the RV-12 plans page 22-03.






See, that wasn't so bad!



Step 5: Fill the tooling holes on the Firewall bottom with blind rivets.



Step 6: Make the F-1201L Bracket from AA6-063X3/4X3/4 aluminum angle per the dimensions given in figure 3 on page 22-03 of the RV-12 plans.

Step 7: Draw a centerline on the forward face of the F-1201L Bracket.



Step 8: Place the Bracket flush against the Tunnel Rib and Firewall Bottom dimples as shown in figure 4 of Van's Aircraft plans on page 22-03. Align the centerline on the forward face of the bracket with the gascolator attach hole. then match-drill #40 the nutplate attach holes in the firewall bottom into the bracket(use a small wood block to protect your fingers.) Remove the bracket and machine countersink the nutplate attach holes in the forward face of the bracket for the dimples in the firewall bottom.
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Step 9: Cleco the F-1201L Bracket to the Firewall Bottom. Match-drill #30 and cleco the two holes in the inboard flange of the bracket into the F-1217-A-R Tunnel Rib (a #30 12 inch extension bit is useful for these holes. Match-Drill #12 the gascolator attach hole in the firewall bottom into the bracket.

Builder's note: I found a 90 degree drill worked better for drilling these two holes.





Step 10: Deburr the Tunnel Rib and F-1201L Bracket. Prime the bracket.

Step 11: Rivet the Bracket to the Tunnel Rib and with a nutplate to the F-1201C Firewall bottom inside the tunnel.



This completes page 22-03. I am really falling behind on getting things posted for the RV-12 airplane. Today is July 5th 2012, but this post is for May 26th. So much time so little to do!!! Strike that and reverse it. The Arlington FunFly is just around the corner, the weather looks good and the camping site is reserved. If Van's Aircraft has any new developments I'll be sure to post it here.

Vans Aircraft RV-12 Build, Section 22: FWD Lower Fuselage (part 2)

Reference: page 22-02, 3 hours

I love the saying someone at worked used, "It's a pace not a race." This is so true when it come to building an airplane. So today will finish the first page of the lower fuselage.The main thing is trying to have regular building sessions rather that marathon days with large lapses of time in between, well that's the plan.

. Step 9: Rivet the nutplates to the F-1217A-L & -R Tunnel Ribs and F-1272 Fwd Fuse Skin per the call outs in Figure 4 on page 22-02 of the RV-12 plans. Rivet nutplates to the F-1201C Firewall Bottom and fwd fuse skin per the call outs in figure 4.





Step 10: Make two F-1201U Firewall Spacers from AS3-020 as shown in figure 3 on page 22-02 per Van's Aircraft.

NOTE: Curve parts slightly by hand for a better fit.



Step 11: Center the Firewall Spacers about the holes used to attach them to the Fwd Lower Fuse Assembly. Place the F-12118 Cowl Attach Plates over the top of the firewall spacers then cleco the hole on the inboard edge of the cowl attach plate and the firewall spacer to the Fwd Lower Fuse Assembly. See figure 4 of Van's Aircraft's plans.

Step 12: Match-drill #30 the holes in the Fwd Lower Fuse Assembly into the F-1201U Firewall Spacers and the Cowl Attach Plates. Remove and deburr the firewall spacers. Machine countersink the nutplate attach holes in the cowl attach plates. Rivet the firewall spacers and cowl attach plates to the firewall spacers and cowl attach plates to the lower fuse assembly.







Step 13:Rivet a nutplate to the forward side of the F-1201C Firewall Bottom to the location labeled "Return Line Clamp" as called out by Van's Aircraft on page 22-02 figure 4.



Step 14: Use a unibit to enlarge the hole between the gascolator attach holes per the dimension given in the RV-12 plans. To kepp the hole centered draw a cross hair out from the hole for reference.

Builder's note: To help this process I drilled a #30 pilot hole before using a unibit.





This complete page 22-02 for the RV-12 aircraft plans. Next time we will get into having fun with fuel tank sealant. Which is not really that bad just messy!

Vans Aircraft RV-12 Build, Section 22: FWD Lower Fuselage (part 1)

Reference: page 22-02, 3 hours

If you are just joining this blog we're building a RV-12 aircraft which is a Light Sport Design by Van's Aircraft.This section deals with building the lower front part of the fuselage.Please note some of the steps were preformed out of order as I am alodining and priming all the parts, and this is why sometime a part will be primed in a picture and then the next shot will show it without primer.

Step 1: Dimple the #40 holes in the nutplate attach pattern Labeled "Return Line Clamp" in the F-1201C Firewall Bottom, flush aft side. See figure 4 on page 22-02 of the RV-12 plans.



Step 2: Machine countersink the nutplate attach holes in the sloped upper flange of the F-1217A-L & _R Tunnel Ribs as shown in figure 1 of the RV-12 plans. Machine countersink all the nutplate attach holes in the F-1272 Fwd Fuse Skin flush on the bottom side. Machine sountersink the upper most hole in the F-1288 Cooler Stiffener.







Step 3: Rivet nutplates to the F-1217A-L & -R Tunnel Ribs and F-1201C Firewall Bottom per the callouts in Figure 1 and Figure 4 of the RV-12 aircraft plans.



Step 4: Cleco, final drill #30 the WD-1204 Engine Mount Brackets to the Tunnel Ribs. Rivet the engine mount brackets to the web of the tunnel rib (not the fwd flange, installed from the bottom side.





Step 5: Machine countersink #30 the holes in the forward flange of the Tunnel Ribs that correspond to the flush rivets called out in Figure 4 on page 22-02 of the RV-12 plans.



Step 6: Cleco the rivet, the Tunnel Ribs to the Fwd Fuse Skin (DO NOT RIVET THE AFT MOST HOLE!.) To this assembly cleco then rivet the Firewall Bottom & Fwd Corner Skin to create the Fwd Lower Fuse Assembly ( Do not rivet the locations labeled "DO NOT RIVET in figure 1 of the rv-12 plans.)







Step 7: Trim the flange of the F-1288 Cooler Stiffener as shown by Van's Aircraft on page 22-02.



Step 8: Rivet the Cooler Stiffener and corresponding nutplates to the firewall bottom.

Builder's note: I completed this step before step 6 of riveting the Lower Firewall assembly together.It worked well and seemed easier to work with.



This completes this entry of the fuselage nothing real exciting just one of those plug and chug projects. Enjoy!

Vans Aircraft RV-12 Build, Section 21: Mid Fuse Ribs & Bottom Skins (part 13)

Reference: page 21-19, page 21-20, page 39-03, page 39-04; 7 hours

There is a lot of ground covered during this entry of the construction of the RV-12 airplane. This will finish up section 21 of Van's Aircraft's Plans for the Mid Fuselage as well as the Auto Pilot servo mount for the elevator control.

Step 1: Dimple all the #30 holes and #40 nutplate attach holes in the area indicated in Figure 1 by Van's Aircraft, in both the F-1213-L& _R Step Floors. DO NOT dimple the nutplate screw holes.



Step 2: Dimple the nutplates shown on page 21-19 figure 1 of the RV-12 plans, then rivet them to the Seat Floors.



Builder's note: In the picture above I am pointing at a nutplate that is installed after the step floors are installed.

Step 3: Rivet the Step Floors to the F-1202F Bulkhead, the F1212-L & -R Step Ribs, and the F-1203A Bulkhead using the rivets called out. Be sure to capture the two holes in the front flange of the F-1253-L & -R Seat Floor Supports when riveting the two outbd holes of the step floors to the bulkhead.





Step 4: Dimple the nutplates shown in figure 2 of the RV-12 plans on page 21-19, then reach through the lightening holes in the Step Ribs and rivet the nutplates to the top flange of the Bulkhead and the Step Floors using the rivets called out.



Step 5: Dimple the four sets of nutplate attach rivet holes in the F-1207B Baggage Bulkhead for the nutplates shown by Van's Aircraft in figure 3 on page 21-19.



Step 6: Dimple the nutplates, then rivet them to the F-1207B Baggage Bulkhead using the rivets called out.



Builder's note: As mentioned earlier I am installing the auto pilot option into the RV-12 airplane. So now is the time to jump to page 39-03.

Reference page 39-03

Step 1: Label, then separate the F-1286A-L & -R Servo Brackets by removing the material shown hatched in figure 1 on page 39-03 by Van's Aircraft.

Step 2: Label, then separate the F-1286B-L & -R Servo Angle by removing the material shown hatched in figure 2 as shown by Van's Aircraft.



This completes page 39-03.

Reference page 39-04; Step 1: Not applicable.

Step 2: Cleco the rivet the F-1207 Baggage Bulkhead and the F-1286A Servo Brackets to the Baggage Ribs using the rivets called out in figure 1.



Step 3: Cleco then rivet the Servo Angles to the Servo Brackets as shown on page 39-04 of the RV-12 aircraft plans.



Step 4: (Preconst)Proceed with the assembly instructions in Section 21.

Reference page 21-19; Step 7: Cleco the Baggage Bulkhead in place, then rivet the baggage bulkhead to the F-1206-L & -R Baggage Ribs using the rivets called out. Rivet to these two ribs only, leave the rest of the baggage clecoed.

Step 8: Install the snap bushings depicted in figure 3 on page 21-19.



Step 9: Cleco the F_1048 Facet Pump Bracket to teh Bottom Skin in the tunnel, then drill #30 the four holes common to both parts.



Step 10: Remove the Facet Pump Bracket, final drill #40 and machine countersink the nutplate attach rivets, then attach the nutplates shwon in Figure 3 with the rivets called out on page 21-19 by Van's Aircraft.



Step 11: Rivet the Facet Pump Bracket to the F-1276 Bottom Skin using the rivets called out.



Builder's note: It doesn't say so in the instructions but it is a good idea to rivet these from the bottom of the fuselage. This completes page 21-20.



Reference page 21-20 Step 1: As shown in figure 1, install the six systems block studs in the holes of the F-1276 Bottom Skin between the two F-1215 Seat Ribs.



Builder's note: In the picture above you can see only 4 of the 6 studs.

This complete not only page 21-20, but also section 21 Mid Fuse Ribs and Bottom Skins. Next time we will start the forward fuselage and lower firewall. I'm going to leave you with a few pictures of the snap bushing that need to be installed for the Dynon Skyview avionics package. These specific bushing live between the seats in the tunnel area. Until then enjoy!