Trevor & Dewey's RV-7 Construction Log

Fuselage - Main

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Date: 09/10/2011
Task: Control Systems

Today I had my first attempt at powder coating. It is dirt simple! I powder-coated the brake pedals black with a light texture. They turned out great! The prep work is the same as a top-coat paint. Essentially we hung the pedals up, connected a negative lead to the safety wire holding them up, held a trigger down and sprayed away. After about 30 minutes in the oven, we removed them to cool off and then they were ready for assembly.

Here is a picture of the first pedal after it was removed from the oven. It has a nice semi-gloss and a great texture.

We then installed the pedals onto the rudder pedal weldments and attached the master cylinders. After installing the bolts and cotter pins, it was ready to be installed in the fuselage. It looks great!

The other part of the day was spent cutting the first revision of our instrument panel. It started as a 45" x 18" piece of 0.62 aluminium. The first and second cuts went really well!

Here the machine has finished all of the inside cuts.

Houston we have a problem! Someone my x,y 0 offset was reset and the outter cut was messed up. Looks like I'll have to come back tomorrow to cut another one.

::Lastly we continued work on the control system. I'm having a problem I can't seem to figure out. The F-789 small pushrod is too short, by about an inch. However, I builit per the plans. I then set the neutral position and found that the rod-end hits the control stick weldment. The only solution I can find is to reset the neutral position of the elevator bellcrank. I'm going to have to call Van's about it on Monday.