Work Begins! + 1st Part Destroyed - Deburring - Airplane Build VLOG #3
HTML-код
- Опубликовано: 17 июл 2019
- Some aircraft parts were harmed in the making of this video.
Proud to be associated with ForeFlight: www.foreflight.com/flightchops/
Visit www.FlightChops.com for behind the scenes and monthly GiveAways!
In this “Airplane Build Vlog” episode of Flight Chops: We begin the work starting with deburring, and destroy our first part :P as we commence the project to build this aircraft!
And if you’re going to AirVenture 2019 - meet us at the Van’s booth on Saturday and win a flight!
The entire schedule is here:
flightchops.com/2019/07/02/fli...
Special thanks to the Canadian Historical Aircraft Association for hosting this build!
Come and visit some time to see the build, visit the museum, and fly some warbirds!
www.ch2a.ca/
___
Huge thanks to all the Supporters on Patreon! Productions like this wouldn't be possible without your help!
For those that haven't seen it, please check the Flight Chops Patreon page to find out how you can be a part of it
/ flightchops
_____
Sponsor / Supporter Links:
ForeFlight
www.foreflight.com/flightchops/
Bose Aviation
www.bose.com/a20
Van’s Aircraft
www.vansaircraft.com/
CloudAhoy
www.cloudahoy.com/P/flightchops/
Infinite Flight
infiniteflight.com/
AOPA
www.aopa.org/
COPA
copanational.org/en/
The Finer Points of Flying - Jason Miller:
adventure.learnthefinerpoints.com
iCloth Avionics:
a.co/4f66Evg
Spectrum Airways Flight Training:
www.spectrumairways.com/
FLIGHT CHOPS DISCLAIMER:
I am a "weekend warrior" private pilot, I fly for fun with no intentions of going commercial. I have had my PPL for over 15 years, but still consider each flight a learning experience - I generally take detailed notes after each flight to remind myself what went well or what I could do to improve.... Having the GoPro cameras to record flights like this is invaluable. I find these self analysis videos very helpful in my constant quest to improve, and am happy to share. Feedback is invited; however, please keep it positive.
Visit www.FlightChops.com for behind-the-scenes content, epic giveaways and search episodes by aircraft type!
That square aluminum piece showing how it should progress is a great idea. Van should include that with the instructions
This is what I've been talking about all these years.
Since I was a small boy, I've been a model builder.
Nothing can equal the pride and the satisfaction that comes from having built it yourself.
The 1/6 scale Taylorcraft in my icon is just one many examples of what passion and dedication can achieve.
Soldier on, Steve! I'll be watching.
This build is awesome.
The team is a treasure.
This episode needs a counter in the corner for every time someone says deburr
About to shut down for the night after a long day of editing build vlog footage - this comment comes in to brighten my evening - appreciated :)
Getting the notification for this video was timely for me; watching it helped alleviate the panic attack I was having about starting to work on the canopy. I have to take advantage of the heat wave we're having this weekend; ideal conditions for working on plexiglass. Doing a LOT of homework to prepare mentally (which probably brought on the panic attack). Volunteer: "Sure wouldn't want somebody to have to do this all by themselves." Me: "Uh... too late!" Van told me personally that 95% of the build can be done by one person, which was very encouraging. But it will take a first-time builder like myself much longer than an experienced builder. But I'm most of the way up the mountain... just keep climbing.
I was twenty three when I built my first house with one other person. I remember walking around putting steel rebar in the footing forms and thinking about how far away I was from sheeting the roof! I asked myself, what have I done? From that point on, I never allowed myself to think beyond the immediate step and what was come up next.. The house was finished in 10 months! I am looking forward to following your build process..
I bought the RV 12 and it is ready for the test flight now.. Have fun Steve, building anything is a great life experience..
“The difference between an adventure and chaos is attitude”
The difference between adventure and chaos is altitude. FTFY
Steve I was a machinist and deburring was a big part of the job that could and was rejected by a customers. We deburred parts that the edge was broken to a max of .003 of an inch. It was quite a chore. You have great instructors enjoy the build.
Love it!!!! I'm an aircraft mechanic by trade in a depot level maintenance shop. A couple things to make deburing easier and faster. For the holes. A 3/8 diameter M.A Ford 100degree chatterless countersink will save you literally hours!!!!!!! Plus they cost like $10. Chuck it up in a slow speed drill and have at it. Personally, air drills are best with their softer start than an electric. As for edge surface finish. A warn down blue(fine) 3" 3M buffing pad in a 90* grinder is the best. Again, literal hours of saved time. The panel you guys took hours to do would have taken maybe 15 minutes total. Use a 3" pad with a 2" mandrel. That way the edge of the pad is flexible and greatly reduces the likelyhood of gouging the part by accident. To use it, use a light draw stroke toward you. One parallel with the part edge to make it smooth. Then a 45* on either side to debur the part.....Done! I'm loving this new series of videos. Keep up the good work. Can't wait to watch the next one.
Link to the chatterless in case anyone else needs them. They are made in other sizes, materials, angles and flute style available from m.a ford.
www.browntool.com/Listview/tabid/344/CategoryID/82/Level/a/ProductID/797/Default.aspx
As a machinist who has done more than my share of deburring, I was wondering the same thing! Countersinks are a real life saver
@@gilmour73 Everything I do gets debured. Literally everything, cars, planes. As well as casting flash removed. It literally drives me up the wall to leave it.
We have lot's more to do through this project, so I will definitely bring these insights to the team!
Oh I know! The amount of times I've picked up a part someone else has made and cut myself is astounding. I watch a lot of RUclips videos where someone will drill a hole (horribly not straight, with a ton of drill wander) then just leave the ragged edge, then bolt it up. Makes me cringe. Don't even get me started on a lot of RUclips videos of people doing lathe work!
@@FlightChops at KOSH ask some of the vendors like aircraft spruce and the others to show you their different deburr tools. There is a great variety for many different applications. Some of the comments above about different methods of drill mountable deburr tools for holes and edges could be of great use to you. I have been greatly inspired by your videos, you helped me keep going while i was working towards my PPL. Keep it up.
I could honestly watch a 2+ hours video of the team talking about what they are doing with just general workshop noise with the grinding wheel going from time to time.
It's such a calm and focused environment.
Great video! Very exciting to see it come together.
Two things:
1. Please capture the frustration and negative moments in the build.
2. Please can you collect total man hour numbers?
This is going to be an awesome series! A coworker/friend built a quick build RV 6! He always liked the RV kits and when Vans introduced the quickbuild kits he jumped on it. It was the 53rd RV6 quickbuild. It was a great build and flew really nice!
I just took my first flight (besides my discovery flight) Monday after receiving my medical certificate this weekend. I did my first takeoff and landing - which was a bit bouncy but was overall just fine. I have two lessons scheduled for next week. I started ground school at my local college 1.5 year ago, did flight lab on red bird simulators, and completed human factors this spring. I hope to achieve my ppl by the end of this year. Just wanted to let you know what an inspiration you and others have been - I've been watching for 4 years I think, as well as Steveo1kinevo, and Mr. Aviation - I wouldn't be doing this if I hadn't have come across your channel!
Steve:
You've still got the best channel on the website! I'm thrilled that we're finally seeing progress on the Van's. I may be speaking only for myself, but I'd love to see you and your team dive a little deeper into technical details going forward. However, I know I speak for everyone when I say that (just like you've always done with your flying) we want to see when you screw up and learn something!
The instructions are very thorough and clear IN THE BEGINNING. The further you get into the build, the more vague the instructions become ---- learn and don't forget early lessons
Thanks for the insight Gwen - remind me what model(s) you have built?
@@FlightChops (mine:) RV12 and assisted others on RV10, RV8, Glastar, Zenith CH-750, and Velocity
Wow! Wanna visit our build some time? I’d love to meet you and pick your brain further :)
So much fun (with a bit of tedium). A few things that I did that made things easier were using a deburring bit in a small cordless screwdriver - something light and low speed. You can get an edge deburring blade tool that you drag along the edges of the skins that's a lot quicker than a file. Also, when removing the vinyl off of the skins, wrap it around an old broom handle - you just roll the vinyl off the skin and onto the handle. Added benefit is that there's no cleanup of piles of blue wrap.
The dreaded leave the plastic on versus taking it off. Pros and Cons of both. Pro is it helps cut down on the scratching in the hanger until paint and it looks pretty. Cons: takes a lot of time to remove the strips, you will leave small scratches no matter how careful you are being, you still have some exposed surface, the plastic gets harder to remove with time (my RV-10 wing kit is 15 years old I speak from experience), there have been some incidences of corrosion starting under the plastic. Also do not prime the strips or the outside skin surfaces. You will just have to remove it later as most, if not all, paints have a maximum amount of time between primer application and paint application (most are 3-7 days). The removing it process will produce far more scratching than it sitting around in the hanger. Glad to have another build to follow when I am not working on my own.
I make parts for hang gliders and ultralight aircraft. I place so much importance on proper deburring, that I don't trust anyone else to do it for me! Of course this build is so big that more people need to be involved. If I was there, I'd be sneaking around checking if everyone did it to my standards. One thing to note is--on sharp bends, if the sharp side of the guillotined edge has to be on the outside of the bend, it should be deburred before bending, otherwise small cracks can be caused by the stretching of the torn edge which may not be visible.
I really enjoy these videos that follow the journey of getting instrument rated and building airplanes. You are a great filmmaker and great adventurer.
Deburr this deburr that deburr everything. Very cool. Right now I'm building an rv12 with my highschool.
Great stuff, this project being documented in the flight chops style is going to add a tremendous amount of value to many walks of life who aren't aware of the artistry, expertise, and passion that goes into building a machine.
Makes me want to continue building my RV-3... I'll keep watching to make sure...LOL !
Really cool. Looks like a great team you have around you. Building an airplane in a hanger with so much history makes it even beeter
I'm helping a friend build his RV-14 while I sit reserve. What a great way to kill the hours of "house arrest". We were classmates in upgrade training when I heard about his project. Its been a fun, educational, process to build not only a plane, but new relationships too. IF ONLY those parts came deburred lol...
Love watching this build Steve. 30 years ago, the only way I could afford the RC aircraft I wanted was to get the plans by mail order, buy the balsa and parts, and do it all myself. Just like you're finding though, I enjoyed the build damn near as much as the flying. These days it's so much cheaper to buy something ready to fly, I really do feel that the craftsmans' knowledge is being lost in the world of aviation. Who will be left to restore warbirds in 10-20 years' time?
In Navy Airframes “a-school”, the school of thought regarding deburring edges of sheet are to:
1. Use fine flat file along entire length in full sweeping motion.
2. Use rounded side of scribe in same manner perpendicular to surface edge to “round” and smooth finish.
This is what I’ve always done and seems to come out almost perfectly with little chance for defect.
Thanks for these insights - I'll share them with the team
Really looking forward to seeing this build play out!!
I'm really really hyped for this series ! Please keep it as nerdy and technical as you can ;)
Congratulations on starting this awesome project! I myself am in the process of building a 14A and was very excited to see you pick the 14 to build!
As for the blueing, unless you are going to make it a polished plane then don’t worry about trying to keep the blueing on, you will sand the surface to prep it for paint anyways. It is simply a waste of a lot of man hours, both when you initially iron off the strips, but also when you later have to take off all of the small remnants when it’s all put together.
Excited to see your project process!
This is great, Steve! Looking forward to seeing this RV come alive with time. Going to be a great day when she flies the first time ever!! I can feel the excitement already ... but I'm getting way ahead of myself here.Back to the grindstone! 😁
Thanks for sharing the process! I've always wondered what it took to assemble a kit aircraft, and I shall soon know. 👍👍
Best thing you can do when a wheel grabs anything is immediately let it go. The build is looking good buddy! Can’t wait to see more
TIP: OCR your manual with a software like ReadIris. Then, via PDF, do your parts searches. DO yourself a favor and get a laser printer inscriber, either loan or second hand (they can get pricy) then inscribe your parts with keys that you can then photograph and recall. Makes life easy down the line.
If presumed you'd just log into the manufacturer's website and be able to reference any part. Thumbing through a paper document doesn't seem like a good use of time.
Could see making barcodes (& having a reader..) for all the parts would be extremely helpful/timesaving..
@@NesconProductions
Absolutely. Perhaps use a fibre laser to cut the parts out and mark them with part numbers, traceability data and barcodes at the same time. Simple phone app to scan the part to link to build manual and the online shopping basket to reorder is you mess one up. I've doing something along those lines for my company.
@@owensparks5013 Err.. not familiar with a fibre laser (making me think about the fellow with the Darth Vader shirt - aka light saber.. lol!), but making larger tags with bar code labels for small parts as Malabanias suggested could see being worth the time making. One thing this project does point to are technologies not necessarily designed for building an aircraft, but very useful making the job easier/quicker. Usually a trade off doing something quicker can lead to messing up quicker as well so a delicate balance building something your life (& others) depends on.
Leave the vinyl on unless you plan to paint it. We are building the RV-10 and are working the horizontal stabilizer. Great work getting a full team to help you!
I am also building, but mine is a Zenith STOL and I am scratch building alone, First part so far, rudder partly skinned. At 42.7 hours build time.
The blue plastic becomes extremely difficult to remove after several months. I would just peel it off as you build since you are painting it anyway. Saves a lot of time. Also Van's doesn't recommend deburring all final-sized punched holes in skins, just inspect. I think it says that in the introductory part of the plans.
Incredibly blessed to have all that help and knowledge....
Thanks FlightChops for sharing!
Forget leaving the blue on. No polishing no need. The longer its on the harder it is to remove. If you are going to alodine and prime it needs to be off anyway. Have fun, my kit arrives in October!
You could not be in a better place to keep you inspired during the build . Really looking forward to your next video
Great episode, awesome! Looking forward to future build episodes!
dunno if anyone has mentioned this, but if you want to speed up the hole deburring i recommend a power drill with a countersink (available from pretty much anywhere). it will remove material way faster so you have to be careful not to put too much of a bevel on the hole.
A friend once told me the most dangerous till in the shop is the buffer, they are looking for ways to grab and throw whatever part you are working on.
Fantastic episode Steve!
Agh, no no no no no do not use the grinding wheel to debur aluminum! Aluminum gums up the wheel, and very quickly becomes less effective, so people press harder and heat up the wheel and it could explode. You can see how gummed up that wheel is at 11:50. Use a belt sander!
Other than that, great video and progress guys, keep it up.
If you’re not polishing, don’t bother with the soldering iron trick, just to much extra work. Also dont sweat replacing parts that got messed up, they are normally very cheap to buy again.
And the extent to which they're deburring everything is tremendous overkill--at least on the edges of the sheets. I've been an A&P for over 30 years and have patched, repaired and fabricated countless parts. Not once have I ever seen a "factory-built" aircraft deburred or stress-relieved to that degree.
So I think some of that would be very advisable--say on the thicker aluminum fittings that may bear a fair amount of stress. But for the majority of parts they're showing being deburred in the video, I think they've gone well past diminishing returns. You just don't find that in the certificated aircraft I've worked on...at least not to the degree shown here. But hey, some of the things I've worked on are only 50-60 years old, so what in the hell do I know?
12:13 Reminds me of that bit in Tommy Boy. "Nice distance!"
This is making me want to build a Kitfox really bad. I blame you, Steve! 😝😂
Haha. Build an RV-14 and put big tires on it :P
I think this really shows how useful flying clubs can be for folks considering home builds.
Being able to lean on others that have had building experience is crucial for first time builds, though obviously not impossible to go without!
I've found the EAA people (in the States) to be fantastic people. I'm not building an airplane but I've gone to many local meetings and met with other local EAA chapters. They're, by and large, super helpful and friendly people. It seems to be a great community. That's half the reason why I would ever even consider building my own airplane.
@@jonthepilot6924 ; my locals are not so great. they have no LSAs and looked down on my questions to learn flying, they seem to be a clique that doesn't care too much for boobs asking newbie questions. Even tho I am an aero engineer, have plenty of tools and willing to help anyone build anything. It appears theres better money to be made in young eagles and teaching them the full PPL instead.
I'm in the pull all the blue stuff off camp, especially if it's getting painted. There just isn't any value to spending all that time carefully exposing rivet holes. The plastic doesn't offer any true protection against impacts or scratches. And it will take much less time during surface prep for painting to remove scratches than you waste removing thin blue strips of plastic. I haven't heard any arguments that really convince me leaving the plastic on does anything.
You never stop learning about whatever you may be doing. You are all doing an outstanding job. If it's not done correctly stress will tear it apart in time. Thanks for letting us watch it being built. Shalom
Love seeing this after doing academic research on homebuilts. I focused on the Pietenpole Air Camper at the time though to its cool to see some of the intricacies of metal working.
Great vid, good job including so many people in the storytelling and not just the story. Made it easy to connect to..
what a great group of friends you have there helping you!
I love your videos - and today you gave us a video, building a plane, with warbirds in the background and an 80's synth soundtrack. OUTSTANDING!!!
Right?! As soon as I found that track I was like - Hell yes! that is a "get it done montage sound track from every 80's film!"
Great!! These are my current favorite episodes!
You get an “attaboy” 👍 from me for this awesome 👏 build. And it’s always cool to have some experience 👨🏼🦳 working side by side when taking on a project like this. I’ll be watching for sure!
word of advice, do not use a grinder to debur the edges. It will cause more burrs, and can cause stress fractures. A piece of crocus cloth or a smooth file is best.
just pull off the blue coating. it is an ALCLAD, which is designed to not allow corrosion to start (i was in the USAF - 2A7x3 - Aircraft Sheetmetal and Corrosion control for 10 years). As long as all parts stay in doors and dry, there is no harm.
Thanks for the tip!
Our grinder wheel actually has two sides, we have a scotchbrite wheel on the side we use for deburring
Very interesting. Look forward to the next one.
Super excited to watch this happen. I’m contemplating building a Sling Tsi, so I’m interested to see how smoothly and fast this progresses.
Thanks for sharing! :-) Happy landings
I haven’t built an aircraft yet, but I have a little bit of soldering experience. For filling down the soldering iron tip to a point, I always use a file for the job. Using a piece of sand paper like that I think wouldn’t be as affective. I don’t know how this method would effect the aluminum or the plastic covering, but this is the most effective method I’ve found. Love the series and happy building!
Yes I am a retired A and P with sheetmetal background and a blue scotchbrite pad works well. There is also 1" and larger barrel sanders in different grits that cut on time to deburr.
Really enjoy your channel, Previously Airline Capt in ME, 26,500 hours, now retired in Mountains of Northern Thailand.( Great fan of Plane Savers.
Wow look at Flightradar24, there’s about a million RVs all heading for this place called “Oshkosh” right now, heh.
I do not think I would ever have the patience for this. Happy to watch you do it, though!
Another excellent video Steve! I wish Lockheed would put that note in the F-16's tech data haha keep those flight chops sharp and those panel edges smooth!
I am building a scratch build Bearhawk four place for close to ten years now, its the best fun but being from German decent does not help, its right or it is right. They say perfection is the enemy of completion. But I know I will not be happy with anything less than perfect. Great job you all
I think it might not be a bad idea to think about moving that grinder somewhere else. I know from personal experience how hard they can throw parts, and having that around all of those priceless warbirds, many of which are fabric-covered, seems like a potential disaster.
Looks like you have a great team Steve! I had to suspend beginning work on my RV12 as we are in the middle of moving..Once we get settled in I am going to join the EAA chapter that is local and hopefully befriend(bribe probably..LOL) some folk to come over and help me get the tail done..Am excited to see how this progresses!
Let's see plans for those build tables...especially the one with the cabinet and extendable tabletop w/support!
Agreed.. Something as basic as those worktables will really make the job a lot easier. Can never have enough table space for such a project..
FlightChops, there are many Aviation Vlogs on youtube ..your's is exceptional . you know what from day one when you said you were not sure what aircraft to buy ..how many seats etc.. I knew you will go for an RV... good luck buddy . !!
Right on! Appreciated!
Wow, this will be an amazing series to follow, you have a new subscriber!
Welcome!
Looking Good
who knew removing stress risers could be so stressful :)
Need to fly it into Oshkosh once it is finished. Collect your dedication reward.
Great video!
You're going to be painting so remove the bluing, since etching is going to scratch it much more than anything you're going to do to it.The blue material isn't that great of protection and the longer the material stays on the harder it is to remove. I had my wing root covers in my garage for a few years and it took a lot to remove the material and those pieces are fairly small.
Great blog, sure wish I had it three years ago!
wow, it will take a lot of pressure off me if I have team like this around me. I am definitely looking for at least one partner to build with me. Hope to see you at Oshkosh next week.
Thanks...!
Be careful to avoid over-deburring holes. My RV-12IS kit doesn't require deburring most holes so I assume the -14 kit is similar. In most cases, if the hole is final sized from the factory, you might only need to debuf one side and very very lightly.
My previous build, an RV-9A, required deburring each and every holes because they were all undersized and match-drilled when assembled.
Thanks for the insight - I’ll be sure the team is careful
Great video! Labor intensive!
This is very entertaining. Someday I hope to build a KitFox and a Mosquito XE.
People who paint their aircraft also keep the plastic installed and cut off the rivet lines.
Some even apply zinc chromate primer on the river lines for extra protection to have it painted before being riveted. Then when the aircraft is ready for paint they pull off the rest of the plastic
Great example of teamwork here were the wooden tables that Dennis built can't underestimate how such will make the entire process go easier. Love the comment by Michael Coffin. I'm sure the kit comes with a list of tools to do the job, but wonder how many (safe) shortcuts/tools there are out there to speed the process? Wonder if there is a needed tools list & an optional list as well? The distinct advantage of power tools is speed but such can also screw thing up a lot faster. Example, I knew immediately how that first part got muffed when I saw it & the grinding wheel. Had a very similar experience smoothing a piece of plastic and ended up a projectile :-P. Will add when using a grinding/sanding/buffing wheel with smaller parts using vice grips (with piece of cloth in teeth to prevent marring optional) to provide more safety distance (hand to wheel), grip and higher stability sometimes very helpful.
One question I'd have for Steve why'd get the tail-dragger version of the RV-14 & not the one with tricycle gear? I'm assuming the carryover to flying other tail-draggers like the Harvard/AT-6, DC-3 and eventually the Spitfire. Can't thank Steve (& crew) enough for allowing all of us to watch & learn. Best wishes to all of them!
Thanks for the insights! and you are correct regarding your reasoning for not getting a nose dragger
Dream team
The guy in the Darth Vader T shirt is from Texas. Texans are the only people who say "little bitty".
You should see my instructions. I have about 50 scaled down plans with material lists. Having something with complete sentences is beyond what some of us get. Then again, I am expecting unlimited class performance, so I guess there is nothing easy about this project.
On the destroyed part, the gentleman is lucky he did not get hurt. Knife making if one of my hobbies and every knife maker has a scar or two from final blade buffering where the buff wheel grabs the blade. I have one and hope that I don't have another one.
Suggestion: See if you can get a PDF version of the instructions, then you could use a tool like Bluebeam to search the entire document for part #'s. Super simple!
That's a great idea.. Would very helpful on a laptop & could speed the process for looking for parts/instructions for the entire team. Wonder if such is available due to the proprietary nature of the blueprints?
thank you to plane savers
So cool. I'm want to do that won day
Could you give a tour of the work areas and explain how the process works?
For sure - good idea!
Can you keep track of and show the number of man-hours it has taken to that point? Or put it in the description box?
Yes for sure - we'll update and share that sort of info as we go
How many bandaids were handed out for sharp metal cuts?
Holy crap, I have been waiting for this video since Steve announce the build. I hope to see details, details, details.
Was this detailed enough or do you want future episodes to go deeper?
@@FlightChops Steve, thanks for your reply. For a deburring video, this was great. Don't get me wrong, I could watch you and your team do this kinda of work all day long. The little things, using a soldering iron to remove film and expose the metal was a brilliant touch. I'm hoping to see as much detail as possible as to tools, actual build steps, understanding the "KIT PLANS" and transferring them into your work. As a subscriber, the deeper the better. I'm sure most viewer would agree, we would really enjoy the build (emphasis on build) and watching you complete your dream. I for one will be there every minute.
Put an ejection seat on it!
Man, I'm so jealous! I'd love to build my own aircraft! =P As a car mechanic, I just love working on projects and this one of those that's on my bucket list for sure! =D
Great video as always, can't wait for the next one! Stay safe up there! =)
Robert Forslund Go Ahead! If you want to build a RV you will start with the tail.. while building save money for the wings.. and so on! If you want it then do it! Its great fun!
@@Spinner1987CH yeah, at the moment other stuff has priority but it is on the todo list! =)
Love your channel! Whiskey Tango Foxtrot... Lol... Clever! (Her Tee shirt)
Is a DRDT dimpler the better dimple press? Could you post a recommended tool kit from those who have many builds under their belt? Flight Chops rocks!
Can you and mojo grip compare the sling tsi he is building and your vans when done?