Yaw Damper Servo Mount

I ordered 200 more 3/32 cleco's from Vans.  Getting a few with each order so I can have plenty for the wings.  I now have ~1050ea 3/32 cleco's!

NOTE: The following is a spin off the plans and into experimental world.  Garmin makes an install kit for both the Pitch and the Yaw Damper servos.  Just buy them for a simple care-free install.

So I wanted to make sure I put in the provisions for the pitch servo and the yaw damper servo now while the tail cone is wide open and easy to work with.  The pitch servo bracket is a no brainer, bolt in place bracket I purchased from Van's.  The yaw damper servo mount kit I also purchased from Van's however it is designed for the RV-14 and not the RV-10.  The good news is that most of it fits right out of the gate.  The support bracket that ties the mount to the bulkhead is where things go off plans and must be dealt with....

To give context, here is what the assembly should look like when installed on a RV-14:

And here is how all the parts go together on a RV-14:

The problem is that the bracket does not align like that on the RV-10.  The bulkhead holes are pre-drilled in a different configuration which leaves things looking like this:

Photo by Parish Moffitt

Notice the holes in the top and bottom of the bracket do not align with the prepunched holes in the bulkhead.  Also notice the center hole is not concentric with the larger hole prepunched in the bracket.

To fix this I did something very similar to what Caleb Tennis posted he did on VAF with this post:

Caleb Tennis' Post

First I fabbed up these doubler plates that will sit on the aft faces of the brackets mount ears to cover that larger pre-drilled hole in the center of the bracket's ears.

 Next I noticed that when everything is cleco'ed into place, there is a pretty good sized gap between the bracket and the bulkhead.  I do not want to just force everything together so I will make a spacer for this issue.

 Next I match drilled the mounting ear doubler plates to the bracket's mounting ears.  Then I countersunk the fwd face of the holes to receive flush rivets because these will go against the spacer later.

 Next I squired on some rattle can primer on these parts because I need to go ahead and rivet these doublers to the bracket mounting ears.  No time to prime with AKZO!

Here are the doublers riveted to the bracket's mounting ears.

 Next I made a spacer out of 0.063" sheet.  I used the bracket as a template to mark and cut it out.
Then I match drilled the center hole of the bulkhead to the whole assembly using a long drill bit.  I clamped the whole assembly well before drilling.

 Next I punched this hole I just drilled up to a #12 to receive a #3 AN bolt.

 This is what I was after.  The ability to unbolt and remove this bracket in the future when I need to crawl into the tailcone.

 Those two bolts need a nutplate on the fwd side of the bulkhead.  I used my nutplate jig to get the job done.  Pilot side...

Co-pilot side...

I will need to countersink these holes for the nutplate mount rivets as I want them to go through the spacer and the bulkhead web.

I will install a nutplate on each side fwd of this bulkhead to receive the bolts.

I will need to dimple these bulkhead holes and install flush rivets on the aft side.  This is because the spacer will lay on top of this area.

Pretty good little task but I am very happy with how it turned out!   Thanks to Caleb Tennis for the ideas I stole from his post!

Today I ordered more cleco's which will bring my total to about 1050ea 3/32".  I want to have plenty by the time I get to the wings.  My theory is more is better with these jig-less assemblies to keep everything as straight as possible.

I have also been working out my plan for adding avionics shelves to the tail cone and working out my plan for provisions for a yaw damper servo. 

I have ordered some sheet stock, extra angle and hardware to do something similar to this:

Photo by http://www.tcwtech.com

I also ordered Van's RV-10 AHRS mounting kit that looks something like this when installed:

Photo by Rodrigo Damazio Bovendorp

And finally I ordered two of these ELT/Strobe mount kits Van's has for the RV-10.  My understanding is that the bracket can be flipped over and used for both sides of the 10.  One on each side will give me plenty of flexibility.

Photo by  Richard "Mouser" Williams

And I already have the Pitch and Yaw Damper Servo Mounts from Van's.  I will have to tweak the Yaw Damper servo mount a little bit since it is designed for the RV-14 but can be used with the RV-10 with a little bit of work.

Here is where I am at with that:

Now on to following the plans!

 Got started tonight by drilling the aft deck to the assembly. First I drilled these holes that go into the F-1010A angle at the top of the bulkhead that ends up being the mounting point for the front HS spar. 

 Then I drilled the sides to the longerons.  Ensuring to drill the holes straight and perpendicular to the deck.

I used the long drill to match drill these tight places.

 Long drill required here.

 Then I match reamed these two holes that get bolts using a #12 reamer.

 Next I centered and clamped this F-1011D to the HS mount bars.

 And used the long drill to match drill the holes to the deck, spacer, and the longerons.

 Then I match reamed the end holes that get bolts using a #12 reamer.

Finally I centered, clamped and match drilled the F-1012D elevator stop to the aft deck and longerons.  Finally I match reamed the end most holes of this angle using the #12 reamer.

Ordered Emp/Tail Cone kit and some tools and consumables

Today I filled out and sent Vans the official order form.  Whew this is gonna consume a lot of money and time!

While ordering from Van's, I went ahead and picked up some pro-seal for gluing in the foam pieces in the elevators, double sided construction tape for riveting the trailing edges of the elevators and rudders, and I picked up the Van's G3X Yaw Damper and Pitch Servo Install Kits for the RV-14 that can be used with slight modification with the RV-10.  It is best to install these items while the tailcone is wide open rather than waiting till later.

I also placed an order with Aircraft Spruce for the AKZO primer I plan to use on the parts.  This is a 2 gallon kit.   Also ordered some drill bits and reamers to replenish my stock.  I will go thru a ton of bits with this build.




















Then went to Cleveland Aircraft Tool and picked up some 1" 3M Cut & Polish/Debur wheels for use with the die grinder.  I found that these things while pricey are the cats meow on deburing all the parts!

Then I went over to Amazon and picked up a spray gun kit from 3M.  This is one of the newish Accuspray PPS system guns.  It comes with these special paint cups that use disposable liners and lids with built in filters.   You can mix right in the cup, spray and then throw away the liner with little to no cleanup.  This gun also uses transparent spray nozzles that are easier to clean and you can toss when they get to cruddy.