Smitty's RV-9A - Experimental Aircraft from Van's Aircraft The RV-9A from Van's Aircraft Howdeeeeee! I'm building an RV-9A from Van's Aircraft. Take your shoes off and sit a spell.
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RV Construction Log
- Horizontal Stabilizer (49:40)
- Vertical Stabilizer (21:15)
- Rudder (32:15)
- Right Elevator (35:45)
- Left Elevator (30:50)
- Inventory & Setup (9:30)
- Left Wing Prep (54:30)
- Left Fuel Tank (45:20)
- Left Wing Skins (46:10)
- Right Wing Prep (34:15)
- Right Fuel Tank (47:50)
- Right Wing Skins (40:15)
- Ailerons (54:30)
- Flaps (40:30)
- Rods and ends (18:45)
- Fuselage Parts List
- Inventory and Setup (7:15)
- FireWall (14:30)
- F-704 Bulkhead (13:25)
- F-705 Bulkhead (14:20)
- Other Bulkheads
   and Longerons

- Tailcone (29:30)
- Center Section (35:15)
- Forward Section (52:40)
- Forward Assembly (24:30)
- Skins/Baggage Area (46:30)
- Seats & Seat Floors (30:15)
- Flaps & Gear Mounts (18:15)
- Fuselage Plumbing (14:0)
- Tail Feathers (16:35)
- Front Deck/Firewall (58:50)
Finish Kit
- Electrical (57:30)
- Electrical Part 2 (24:0)
- Canopy (22:30)
- Landing Gear (18:35)
How I Did Stuff
Pop-Rivet Dimpler 101
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Wing Cradle Mod
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Delrin Aileron Stops
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Paint Possibilities
Top Skins and Baggage Area - 6/7/2009
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Drilled the F-757 Gussets into placeDrilled the F-757 Gussets into place
Here's last thing to do before deburring, dimpling, and priming these parts before riveting. I drilled these 1/8" holes for the flat head rivets that will go into the longeron.
First things firstFirst things first
The F-757 gusset must get riveted first. The instructions don't mention this, but it has to be. The F-721B side rail actually touches the rivets in the gusset and would definitely get in the way. After I riveted the F-757 gusset in place, I clecoed on the F721B side rail and started riveting it.
This took a really LONG time to rivet in place. I couldn't use my hand and pnuematic squeezer because it wouldn't go over the flange on the under side of the F-721B side rails. Then I noticed that my regular bucking bar wouldn't fit behind the flange either. Dammit! Keep reading....
Here's the solutionHere's the solution
A few weeks back, I ordered this really thin bucking bar, not knowing whether I would use it or not. Turns out, I got real lucky on this own. This thin bucking bar was just the right size to fit behind the F-721B side rail flange, alowing me to rivet the rails into place with the rivet gun. Did you notice the Home Depot chisel? I had to use head of this chisel to get the end rivets of the rail. the bucking bar wouldn't reach those rivets.
Time to work on the F-695 Firewall GussetsTime to work on the F-695 Firewall Gussets
I marked the positions of the drill holes on these pieces and drilled the 1/8" holes with the drill press.
Drilled the F-695 gusset to the firewall and longeronsDrilled the F-695 gusset to the firewall and longerons
The gusset didn't exactly fit like I thought it should. The angle against the firewall looked off to me. So after going on Van's Air Force and talking with some other builders, I decided to trim this gusset a little to make it fit better.
These rivets are really close together. I started off using my longeron yoke on my pneumatic squeezer and then switched to my 4 inch no-hole yoke to get the rivets that farthest from the edge of the gusset.
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This website was built to document the construction of an RV-9A in compliance with the FAA requirements needed to certify the aircraft. Any experiences and/or comments are by no means to be considered as instructions on how to build an RV-9A or any other aircraft. Please read our Disclosure for details.
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