Brian & Brandi's Van's RV10 Build


by Brandi Tuesday, February 07, 2012

This weekend we decided to tackle the rear windows and the windscreen. Brian already had them fitted and ready to go so it was pretty painless. The Lord Adhesive we bought came in 50ml packages with a mixing nozzle and an adapter for a regular caulk gun. We used approximately 100ml for each rear window and a little less than 150ml on the windscreen. After experiencing Weld On with the one door window, I'm so thankful we didn't go that route with the rear windows and the windscreen. It was messy enough as it was without the added complications from the stringy & fast curing Weld On. The Lord Adhesive stays workable for just the right amount of time to make some nice fillets on the inside and clean up any mess that oozed out on the exterior.

We didn't have the E-glass needed to finish up the windscreen but I did manage to get fairing filler applied between the plexiglass and the metal fuselage. I've read about guys using black ink toner to color the epoxy filler mix but I had already purchased some West System 423 Graphite Powder for some carbon fiber stuff I've been working on so that's what I used mixed with West System 407 Low-Density Filler. The 407 filler is already a dark brown/burgundy color and the added graphite powder made the epoxy/filler mixture a nice shade of black.

Window attached to left door

by Brian Wednesday, October 12, 2011

We did a lot of sanding and fine trimming to the plexiglass window for the left side door. Once we were happy with the fit we went ahead and mounted the window to the door with weldon. This was a sloppy mess and we're not too thrilled with the result. We masked everything off and moved quickly and it turned out ok but we didnt get a nice fillet on the inside of the window edge. We'll have to go back and fix this cosmetic detail at some point or cover it up with our interior.

After speaking with our good friend Geoff, we decided to try using the Lord adhesive for the windows instead. Geoff and several other people have had good results with it and there is a buzz in the community as to whether or not the weldon is partially responsible for cracks in the paint due to uneven shrinking/expanding of the different materials. Supposidly the Lord adhesive should give a little more flexibility than the weldon and worst case scenario it sure will be easier to work with! It cost a little bit more to go with the Lord adhesive but if it means no cracks in the paint then its worth it. The weldon was about $60 for 5 windows worth and we bought 12 each of 50ml tubes of the Lord adhesive for just under $200. There was a price break at 12 tubes and we figured it would take us about 10 tubes to finish the remaining 4 windows. Kind of a lot of $ in my opinion but this does give us a couple extra tubes for other various things and again, if it prevents cracks in the future it will be worth it. Since we have one window that is already done with weldon, we'll have an interesting test case to provide to the community in the future.

Advice - wait until after the door is perfectly fitted including the latch mechanism before you install the window. Having the window on the door just makes it heavier and harder to work around and its not necessary to install the window so soon like the plans have you do.

Thanks Uncle Ben for holding down the fort! :)

Door video

by Brian Monday, September 26, 2011

I made a quick video of the operation of the door latch system.

One thing to point out that the video doesnt show is to give some more detail about the lock. This is the lock that came with our ACS ignition switch. This works out great because the same key will fit our baggage door, pilot side door, and ignition. I made a metal bracket to give it more stability. There are some photos which show the final product. Also, the door lock was placed on the aft side of the door handle, which means the door handle covers the lock on the outside of the door. This just kind of ended up this way and fortunately worked out just fine. There is a little play before the lock catches the gear so in order to lock the door, the handle must be turned about 30 degrees to expose the lock. It actually looks pretty neat on the outside because the lock is almost completely hidden when the door is shut. Probably very slightly more aerodynamic like this too.

Doors underway

by Brian Tuesday, August 09, 2011

I've been dreading the doors as most -10 builders indicate they are the most difficult and problematic. After a few weeks of putting them off and doing any little other thing that I could I started running out of things to do so I had to start on them. I went slow, followed the directions and began the unpleasant task of trimming all the edges. That wasnt so bad. Next, the plans have you line up the inner and outer door shells and cleco them together via the pre made pilot holes. The pilot holes didnt line up! Panic ensued! Got lots of good feedback from and kept pressing on. Then I had an epiphany! What makes a difficult task really easy? Well, delegate of course! So little Brandi is now the proud owner of section 45, doors, all that is evil. I used to think I was a really fortunate guy to have a wife who was helping build. Now I think that I just might be the smartest builder to date. :)