User Manuals: Van's Aircraft RV-8 Tandem Homebuilt

Manuals and User Guides for Van's Aircraft RV-8 Tandem Homebuilt. We have 1 Van's Aircraft RV-8 Tandem Homebuilt manual available for free PDF download: Construction Manual

Van's Aircraft RV-8 Construction Manual (174 pages)

Brand: Van's Aircraft | Category: Aircrafts | Size: 59 MB

Table of Contents
3
A Word about the Plans
3
Certification and Registration
5
Section 2: Design Philosophy
6
Tools and Workspace
7
Stationary Tools
7
Hand Tools
7
Builder's Tool Requirements
8
Rv-14 Builder's Supplies Requirements
10
Parts Designation System
11
Workspace Required
11
Mechanical Drawings and Mechanical Drawing Reading
12
Ortho Views
12
Drilled Hole
12
Drilled and Threaded Hole
12
Parts Index
13
Aluminum Priming & Painting
21
Section 5: General Information
21
Color Scheme
22
Painting Health Hazards
22
Painting
22
Masking
22
Edge Finishing, Hole Deburring & Scratch Removal
23
Rib Flange Faceting
23
Rib Flange Prep
23
Marking Parts
24
Riveting
24
Removing Rivets
24
Modify Side Cutters
24
Methods for Setting Rivets
26
Fabricating the Wedge Tool
26
Setting Blind Rivets
26
Wedge Tool Fabrication
26
Cherrymax Rivet Installation
27
Rivet Size
27
Proper Installation
27
Rivet Hole
27
Countersinking and Dimpling
28
Machine Countersinking
28
Dimpling
28
Rivets and Sheet Thickness
28
Back Riveting
29
Folded Trailing Edges
29
Homemade Bender
29
Bulged (under Bent) Trailing Edge
30
Properly Bent Trailing Edge
30
Over Bent Trailing Edge
30
Trailing Edge Tool
30
Riveted Trailing Edges
31
Guide and Cutter Setup
31
Countersinking Wedge
31
Double-Sided Tape
31
Riveting the Trailing Edge, Initial
32
Straightening the Trailing Edge
32
Rolled Leading Edges
33
Lap Joints
33
Forming Aluminum Parts from Sheet
33
Vinyl Coating
33
Fluting
34
Aluminum Tubing
34
Steel
34
Installing Nutplates
35
Fuel Tank Sealant
35
Applying Sealant
35
Fiberglass
36
Prepping the Cowling for Paint
36
Tips for Fiberglass Fairings
36
Resin Application
36
Acrylic Canopy and Lexan Window Hints
37
Safety
37
Handling
37
Fiberglass Bonding, Cracks, Etc.
37
Nut and Bolt Torques
38
Fasteners as Pivot Points
38
Ms Nuts
38
Electrical
39
Electricity
39
Wiring
39
D-Subs
39
Backshell Assembly
40
Shielded Wires
40
Molex Connectors
40
Electrical Connections
41
Closed Barrel Terminals
41
Crimping
41
Correct & Incorrect
41
Terminal Installation Table
42
Open Barrel Terminals
43
Electrical Troubleshooting
45
Control Module
45
Continuity Test
45
Basic Checks
45
Glossary of Electrical Terms
48
Ems
48
Gps
48
Trim
48
Compression Fittings in Plastic Tubing
49
Nylon Fluid Fittings in Plastic Tubing
49
Drilling, Taps and dies
49
Drilling Terminology
49
Dimensions
50
Some Notes on Taps
50
Hardware Reference
50
Nas1149 and An960 Washer Substitution
51
Blind Rivet Identification
51
Fluid Fittings
52
Pipe Thread Fittings
52
Npt Sizes
52
Rod-End Bearing Reference Chart
52
Flared Fittings
53
Fitting Identification
53
Conclusion
54
Building the Wing
65
Getting Ready
65
Preparing the Main Spar
65
Assembling the Rear Spar
65
Preparing the Wing Ribs
66
Assembling the Wing Skeleton
66
Main Rib/Spar Assembly
66
Fitting the Wing Skins
66
Assembling the Fuel Tanks
67
Fitting the Attach Angles to the Spar and Rear Tank Baffle
67
Fitting the Tank Skins to the Ribs and Rear Baffle
67
Final Preparations
67
Closing and Finishing the Tank
68
Riveting the Wing Skins
68
Wing Skin Preparation and Assembly
68
Assembling the Wing Leading Edge
69
Installing the Leading Edge
69
Riveting the Top Skins
69
Installing the Aileron Brackets
69
Flaps
70
Attaching Ailerons to the Wing
70
Attaching Flaps to the Wing
70
Wing Tip Installation
70
Firewall
73
Rv-8 Forward Fuselage Floor
73
Section : 8 the Fuselage
73
Rv-8 Cooling Air Ramp Assembly
74
Rv-8A Forward Fuselage Subfloor Assembly
74
Rv-8A Cooling Air Ramp Assembly
74
Rv-8 Landing Gear Box Assembly
74
Rv-8 Forward Fuselage Sub Structure
75
Rv-8A Forward Fuselage Sub Structure
76
Center Section
77
Seat Rib Subassembly
78
Longeron Bending
80
Rv-8 Fwd Fuselage Structure
80
Rv-8A Fwd Fuselage Structure
81
MID Fuselage Skins and Structure
81
Joining the Rv-8 Fwd & MID Fuselage Subassemblies
82
Joining the Rv-8A Fwd & MID Fuselage Subassemblies
82
Tailcone Bulkheads
83
Aft Fuselage Assembly
84
Adding Tailcone to Fwd Fuselage
84
Drilling Fuselage Skins
85
Preparing Fuselage Parts for Final Assembly
87
Fuselage Final Assembly
89
Skin Riveting
90
Note on Battery Location Choices
91
Rv-8 Forward Bottom Skins
91
Rv-8A Forward Bottom Skins
92
Rv-8A Main Landing Gear Mount Installation
93
Rv-8 Main Landing Gear and Tailwheel Installation
93
Rv-8A Main Landing Gear Insallation
94
Rv-8A Step Installation
95
Front Seatback
95
Rear Seatback
95
Seat Floors
96
Rv-8 Consoles and Seat Ramp
97
Rv-8A Consoles and Seat Ramp
98
Empennage Attachment
99
Elevator Control System
100
Rudder Stops
102
Flap Motor
102
Rudder Control Cables
102
Rudder Pedals
102
Fuel System
104
Brake System
105
Aft Upper Skin and Bulkheads
105
Fwd Upper Fuselage
106
Baggage Door
107
Manual Elevator Trim Cable Installation
108
Wing/Fuselage Assembly
109
Wing Root and Flap Intersection Fairings
110
Installing the Slide Rails
113
Preparing the Canopy Frame
113
Fitting the C-801 Plexiglas Bubble
113
Section 9: Fitting the Canopy
113
Fitting the Canopy Skirt
114
Installing the Canopy Latch
114
Installing Windshield Molding Strip
114
Engine Mount
117
Installing the Rv-8 Main Gear Axles and Brake Assemblies
117
Installing the Rv-8A Main Gear Legs, Wheels and Brakes
117
Brake Lines
117
Installing Rv-8 Gear Leg Fairings
118
Rv-8 Main Wheel Fairings
118
Wood Gear Leg Stiffeners on the Rv-8A Main Gear (Optional)
119
Installing the Fiberglass Rv-8A Main Gear Leg Fairings
119
Installing the Rv-8A Nosewheel
120
Setting the Breakout Force of the Nosewheel
120
INSTALLING the WHEEL PANT and U-713C SUPPORT BRACKETS
120
Installing the Rv-8A Nosegear Leg Fairing
120
Rv-8A Main Wheel Fairings
121
Intersection Fairings
121
Finishing the Wheel Fairings
121
Empennage Fairing
122
Wing Root Fairings
122
Engine and Propeller Selection and Installation
125
Recommended Engine Installation Manual
125
Installing the Engine Mount to the Fuselage
125
Conical Engine Mount Installation
125
Oil Pressure Gauge Line
126
Fuel Pressure Gauge Line
126
Manifold Pressure Line
126
Primer System
126
Engine Selection
127
Propeller Selection
127
Disadvantages
127
Constant Speed Propellers
128
Installing Constant-Speed Propellers
129
Installing Fixed Pitch Propellers and Prop Extensions
129
Specific Props for Rvs
129
Matching the Engine to the Propeller
129
Engine Identification
130
A Guide to Lycoming Four Cylinder Parallel Valve Engines
131
Service Instruction
137
Conversion
137
Front Mounted Propeller Governor
137
Rear Mounted Propeller Governor
137
Propeller Governor Oil Line Nut and Elbow
138
Typical Engine Plumbing Diagram
139
Typical Installation of a Control Cable to the Mixure or Throttle Arm
139
Fitting the Cowl, Spinner & Cooling Baffles
141
Air Filter Systems
141
Before Fitting the Cowl
141
Installing the Hinges
141
Fitting the Upper Cowl
142
Fitting the Lower Cowl
142
Modifying the Cowl for the Rv Nosegear Leg
143
Installing the Inlet Ducts
143
Installing the Oil Filler Door
143
Protecting the Interior of the Cowl
143
Engine Baffle Installation
144
Maximum Baggage Weight
155
Aircraft Weighing
155
Staying in the Envelope
155
Section 14: Weight and Balance
155
Rv-8 Weight and Balance Sample Calculations
156
Some Examples
156
Rv-8/8A Weights and Limits - Easy Reference
156
Empty Aircraft
156
Rv-8 Weight and Balance Calculations
157
Final Inspection and Flight Test
161
Pre First Flight
161
Inspection and Preparation of the Airframe
161
Preparation and Inspection of the Engine
162
Inspection (Introspection?) and Preparation of the Pilot
162
Pre Flight Planning
163
Weather
163
Emergency Plans and Procedures
163
Selecting the Right Airport
163
Perform a Preflight Check
164
Other Important Preparations
164
Taxi Tests
164
That First Flight
164
Landing
165
Expanding the Envelope
165
Post First Flight
165
Pertinent Thoughts
165
Stability Investigations
166
Flight Test Procedure:
167
Directional (Yaw) Stability
168
Lateral Stability Flight Test
168
Stall Testing
169
Spin Testing
169
GPS Tests for Airspeed Calibration
170
Limit Testing
171
Flutter Testing
171
G-Load Testing
171
Maximum G-Load
171
Airspeed Indicator Markings
172
Aerobatics
172
Recording Flight Test Data
172
Airspeed Calibration
173

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