Section 19 - Stall Warning System

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	Section Hours: 6.8	Section Status: Complete

Ok, this is gonna take some 'splainin'… We're not installing the Van's stall warning system, however we are installing the access panel from the same section of the plans. In fact we're installing one in both wings so we had to order an extra. You see, due to multiple reasons (future availability of aviation fuel, unsure of our exact engine, unsure of our exact fuel injection system, etc, etc, etc...) we're going to do like a bunch of RV-10 builders and install a port in the fuel tanks to allow the attachment of a fuel return line incase we need it in the future. Chances are we won't, but it's easier now, and not that big of a deal to install it and cap it off. I think the biggest issue was deciding how to do it. Quite a few builders install it on the wing root side of the tank, and we seriously considered that, but there's a lot of stuff in that area & I wasn't sure where to put it that wouldn't cause interference with the existing fuel lines, the aileron torque tubes, etc. In addition, since the fuel returned to the tank would be quite hot its not a good idea to just dump it back in the tank at the wing root since the fuel pickups are right there. So, going in the wing root side requires plumbing a line inside the tank across a few bays so the hot fuel is mixed with the cool fuel in the tanks away from the pickup. Instead, I decided to take the easy way out now and install a fitting for the return line in the outboard side of the tank. It's a minimum of work now, but should we need it in the future, will require a bit more work then since we'll be running a line behind the tank. Anyway, Angela mentioned it would be a good idea to be able to inspect the caps on the fittings, and these access panels are in the perfect place to do that. So, here we are!

Page 2, Step 1: We ain't doin'!

Page 2, Step 2: Cleco the doubler on.

February 21, 2007: First up is to cleco the double plate in the proper location.

Page 2, Step 3: Match drill the holes.

February 21, 2007: After properly locating the doubler plate its time to drill the 4 nurtplate attachment holes in the corners to the skin and cleco them. These holes are used to identify the corners of the area to cutout in the skin. After that, the doubler attachment holes are match drilled to the skin (the holes around the outer edge of the doubler plate). These holes are the ones that will be used to rivet the doubler plate to the skin (on the inside).

Page 2, Step 4: Enlarge the corner holes and cut the access panel hole out.

February 21, 2007: After the holes were drilled, I used a unibit to open the 4 corner holes up to 1/2".

Then just simply connect the edge of the holes with a line to mark where to cutout.

And then using the same technique for the landing light cutouts I finished the cutout for the access panels. (Note: Don't forget to check that the access plate actually fits in this cutout... I did... see step 8 below)

Page 2, Step 5: Remove reference tabs from the doubler.

February 21, 2007: There are a couple of tabs on the doublers that are used to cleco the doublers to the skin. After all the holes are match drilled in the skin and the doubler removed, these tabs are simply cut off... Did it!

Page 2, Step 6: Debur, dimple, & prime.

February 21, 2007: Next all the rivet and screw holes in the doublers & panels were final drilled to remove burrs. The plans didn't say to do this for the screw holes so I tried dimpling a couple… they both cracked. So, I final drilled the remaining ones. Anyway, here are the panels and doublers after dimpling.

Page 2, Step 7: Rivet on the nutplates, and then the doublers to the skin.

March 6, 2007: While riveting nutplates in various places on the leading edge skins I decided to also attach the nutplates on the access hatch doubler plates. I won't rivet these to the skins though until they are back in the cradles and at least clecoed back together.

March 8, 2007: After Angela's help with riveting a bit more of the leading edges, I wanted to do one last thing before calling it a night. So, I installed the access hatch doublers.

Page 2, Step 8: Install the access panel.

March 13, 2007: Ahhh yes… One of those DUH moments again. When I went to screw the access hatch plates on tonight I realized something… I realized I never actually checked to make sure the cutouts in the skins fit the supplied cover plates. Slight oversite! The interference you see here was typical of a few corners. No biggie, but since I have the doublers already riveted on I'll have to make the adjustments to the cover plates instead of the cutout in the skin. This just means that the cover plates will now be "custom fit" since I'll be sanding them down to fit their particular opening... so don't loose them!

There, that looks better.

Everything Else: We ain't doin' it!