Jessen RV-10 Builder's Log
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Vertical Stabilizer
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Section 6

The VS is finished!
Long live the VS!

At 12:11 pm, on May 15, 2005, I began the actual construction of the Jessen RV-10.  It is being built in memory of my father, who always wanted to learn to fly, and in spirit with my children, one who does fly and one who loves all things, big and small.

Total time for the VS = 35 hours

Here the VS components are laid out prior to starting.  I'm now on the Tailcone as I write this and to me it looks so simple.  Didn't look simple when I started!   One step at a time.  It both gets more difficult and easier at the same time. 
Page 6-2  (5 hours)
Step 1.  The plans call for you to begin the project by cutting some reasonably thick aluminum, which you do on the bandsaw, namely some material off the two VS-1014 pieces.  Cut on the outside of your marking line, so you can preserve enough aluminum that can be sacrificed when you clean it up on the scotch bright wheel.  Make cutting outside the line a habit.  If you cut on the line, by the time you clean up the edge, you will not have the correct measurement.  

Also, make sure your camera is ready.  Mine wasn't (I think I was too excited) and consequently, I don't have a shot of my first cut. 

05/15/2005  -  1 hour    bandsaw

Step 2.  Make sure the edges of the cut spar caps have been deburred and polished and cleaned of all debris, then snug these two spar caps inside the VS-1003, as depicted in the plans.   The cut part goes against the web.

Once all clamped in place, begin drilling every 4th hole or so in the web.  1/8" drill.  When finished, deburr the holes, then put everything back in place. 

05/15/2005   1 hour
Step 3.   Next is to drill the holes in the VS-1003 spar flanges that are against the spar caps.  Do this with a #40.  Of course you've secured the caps with clecos and clamps to pull it tight against the flanges.  Once done, remove, deburr, reassemble.   

05/15/2005  -  1 hour   

Step 4.  Lots going on here.  First deburr (and maybe straighten a little if its too bent) the VS-1008.  Then cleco that to the VS-1003, the spar caps and the VS-1010 hinge plates.  Cleco on the other hinge plates, as well.  Drill out the holes according to the plans. 

Then, with a 3/16" bit, drill out the upper attach bolt holes.   

05/15/2005  1 hour

Step 5.  Machine countersink the holes indicated in the plans, namely all those below the upper attach bolt holes.  Do so on the forward side of the VS-1008 spar doubler. 

Note:  If you don't have a drill press, you can do this free hand.  But it is so much more precise using a countersink bit mounted in a simple table top drill press.  Believe me, there are some really onerous things one has to do (drilling out dozens of rivets) later on if these countersinks are not done properly up front.  As you can see in the picture, I did these freehand.  It's fine to do it this way, and in some cases you don't have a choice.  But here you do, so don't.  Do it right. 

05/15/2005   1 hour
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