Jessen RV-10 Tailcone Main

Tailcone
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Section 10

The Tailcone is finished!
Long live the Tailcone!

The Tailcone was started on 11/07/2005 and finished a little over a year later. There were several breaks during that time, so the actual time it took was less, but at this rate the plane will take at least five years to finish, which is much too long. I will soon be making a decision to sell my slow build wings and go all quick build, or not. First, however, I'll go back to Section 9 and finish the elevators and trim tabs.

Page 10-2

Step 1. The first thing to do is make what will become the holder for the aft tie down ring. I messed up with the first one because my band saw blade was too loose. It wandered and I ruined the piece. I got another from Van's and went from there. Also tuned up the saw. It's a simple step, just three cuts.

The next part of this step is to tap the aluminum ingot with a 3/8 x 16 tap. Make sure the hole is drilled appropriately, a good use of your drill press. Tapping with some kerosene helps. I think I used some air lube oil, which worked but I do not recommend it. Too sticky. Turn the tap a rotation, then back it up to break the bead, or whatever it's called. Then turn again a full rotation, back it up, and so on. Go all the way down.

11/08/05 - 60 minutes Band Saw; Tap Set

Steps 2, 3. First cleco the F-1012 A&B together. Then draw lines on the back of the F-1012E so you can accurately put it in place on the F-1012A for drilling. Careful. Slippery. Once clecoed in place, match drill the three pieces.

11/08/05 - 30 minutes

Step 4. F-1011E rudder cable angle. Nothing hard here, just make sure you measure the 13/32 from the back of the piece and not the inside bend. Again, cut it 1 mm too long to allow for deburring.

11/07/2005 - 20 minutes Bandsaw, #12 drill bit, punch

Step 5. Here you attach nut plates to the F-1011E so you can drill out the required rivet holes. You can see the holes in this picture.

11/07/2005 - 20 minutes

Step 6. F-1011A Bulkhead stiffener is cut from one of the 6 foot lengths of j-channel. Deburr it and then you'll draw a rivet line in the next step on the next page. I used the Dremel here since the material is rather thin.

11/07/2005 - 20 minutes Dremel