Tools

I've done a lot of research into the tools required to build the RV-10.  There are a few companies that sell full sets that you can buy in one fell swoop.  I'd like to spend a little less and get more for my dollar, so I did a lot of hunting.

The main source of my tools actually came from my wife.  Her ex-coworker's brother-in-law had built an RV-8 about 10 years ago and recently sold it.  We worked out a deal and we met in the middle which was a two hour drive for both of us.  This is what I ended up with.  Not pictured is a toolbox I got also.


There's a TON of stuff in there, I think this was a real good deal for around $1200.  On top of that the seller was an extremely cool guy, retired from flying wide bodies, current corporate pilot.  We had dinner and split, but I could have talked with him for hours.

I picked up a used squeezer ($400) and angle drill($100) on ebay.  Squeezer bodies alone are $600, and this one came with adjustable set, quick pins and a 3" yoke.  It was used to build the tail and wings of a Glassair Sportsman by a couple in Wyoming. The DOTCO drill sells new for $1000.

Here's the DRDT-2 dimpler.  Heavy beast.  I made a side shelf on one of the benches to mount it to instead of building tables to support the skins while you dimple.

Here are some test dimples.  I adjusted it so that the dimple ties touch the skin to be dimpled, then drop the ram another half turn to put a good clamp down.  This half-turn setting was found by some experimentation.  I tried different settings between having the dimples just touch the skin all the way to a half-turn of clamp-down.  Each time a precision square was laid across the dimple to see how much the skin was deflected.  1/3 turn left some deflection on both #30 and #40 holes, 1/2 turn seemed to make it as straight as it was going to get. I read online that the "halos" are ok and it means you are creating a full dimple.

Here is the band saw I'm using.  It technically on long term loan from my dad.  Bought a new blade for it, here's the info:
29785D2B41425 Diemaster 56-1/8 in (4 ft 8-1/8 in) x 3/8 x .025 x 10/14tpi VR

It's a 3/8 blade and probably stretches the limit of what the saw can handle, but it sure cuts the AL like butter.

This is a bucking bar made from nearly pure tungsten.  Its amazing dense.  This little guy weighs 1.5lbs, more than the steel ones that are significantly bigger.  Expensive, but really helps do the job better.

About the RV-10

Van's RV-10 is a 4-place plane capable of carrying 4 adults, 100 lbs of bags, full fuel at 200mph for 800-1000 miles on one fillup.

I looked at other planes, especially the Velocity, but in the shop space I have a fiberglass aircraft was just not going to work.  Van's planes, being assembled in pieces, make working in smaller shops much more doable.

There are lots of certified planes out there for sale and seemingly great prices.  The problem with them is that they are heavily restricted on what modifications you can make to them and who can do the maintenance.  There's lots of complaints by certified aircraft owners of light bulbs, trim pieces and simple hoses costing hundreds of dollars. Avionics are similar, you are mostly stuck with round analog gauges.  Being an avionics guy, I want to look at glass.  I've been working on advanced cockpits for my whole career, I won't accept flying something that was cool in 1960.

Here is Dynon's latest display.  Rivals the stuff we put on $50M jets for the top 0.1% .

Another factor is builder support.  Its hard to argue VansAirForce isn't the best home builder community on the net.  You ask a question and within hours (sometimes minutes) a slew of experience builders are there to help.  Plus the factory is a phone call away.

My main mission is long range cruise.  I don't do aerobatics or crazy stuff.  Boring, safe flights are just the way I like to fly.   I want to take my family on trips to see the USA, its a big country with tons of awesome stuff to see.  So cruise efficiency and speed are important.  The RV-10 will conservatively go 160-165 knots (190mph) while burning 10-12gph.  There are better cruisers out there, but none of them land as slow.

Here is Van's RV-10 page.

Here is Tim Olson's excellent flying example: