Name: Van's Aircraft RV-8
Brand: Van's Aircraft
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VAN’S

RV-8/8A

CONSTRUCTION

MANUAL

VAN’S AIRCRAFT, INC.

14401 KEIL ROAD

AURORA, OREGON USA

503-678-6545 FAX 503-678-6560

www. vansaircraft.com support@vansaircraft.com

Table of Contents3
A Word about the Plans3
Certification and Registration5
Section 2: Design Philosophy6
Tools and Workspace7
Stationary Tools7
Hand Tools7
Builder's Tool Requirements8
Rv-14 Builder's Supplies Requirements10
Parts Designation System11
Workspace Required11
Mechanical Drawings and Mechanical Drawing Reading12
Ortho Views12
Drilled Hole12
Drilled and Threaded Hole12
Parts Index13
Aluminum Priming & Painting21
Section 5: General Information21
Color Scheme22
Painting Health Hazards22
Painting22
Masking22
Edge Finishing, Hole Deburring & Scratch Removal23
Rib Flange Faceting23
Rib Flange Prep23
Marking Parts24
Riveting24
Removing Rivets24
Modify Side Cutters24
Methods for Setting Rivets26
Fabricating the Wedge Tool26
Setting Blind Rivets26
Wedge Tool Fabrication26
Cherrymax Rivet Installation27
Rivet Size27
Proper Installation27
Rivet Hole27
Countersinking and Dimpling28
Machine Countersinking28
Dimpling28
Rivets and Sheet Thickness28
Back Riveting29
Folded Trailing Edges29
Homemade Bender29
Bulged (under Bent) Trailing Edge30
Properly Bent Trailing Edge30
Over Bent Trailing Edge30
Trailing Edge Tool30
Riveted Trailing Edges31
Guide and Cutter Setup31
Countersinking Wedge31
Double-Sided Tape31
Riveting the Trailing Edge, Initial32
Straightening the Trailing Edge32
Rolled Leading Edges33
Lap Joints33
Forming Aluminum Parts from Sheet33
Vinyl Coating33
Fluting34
Aluminum Tubing34
Steel34
Installing Nutplates35
Fuel Tank Sealant35
Applying Sealant35
Fiberglass36
Prepping the Cowling for Paint36
Tips for Fiberglass Fairings36
Resin Application36
Acrylic Canopy and Lexan Window Hints37
Safety37
Handling37
Fiberglass Bonding, Cracks, Etc.37
Nut and Bolt Torques38
Fasteners as Pivot Points38
Ms Nuts38
Electrical39
Electricity39
Wiring39
D-Subs39
Backshell Assembly40
Shielded Wires40
Molex Connectors40
Electrical Connections41
Closed Barrel Terminals41
Crimping41
Correct & Incorrect41
Terminal Installation Table42
Open Barrel Terminals43
Electrical Troubleshooting45
Control Module45
Continuity Test45
Basic Checks45
Glossary of Electrical Terms48
Ems48
Gps48
Trim48
Compression Fittings in Plastic Tubing49
Nylon Fluid Fittings in Plastic Tubing49
Drilling, Taps and dies49
Drilling Terminology49
Dimensions50
Some Notes on Taps50
Hardware Reference50
Nas1149 and An960 Washer Substitution51
Blind Rivet Identification51
Fluid Fittings52
Pipe Thread Fittings52
Npt Sizes52
Rod-End Bearing Reference Chart52
Flared Fittings53
Fitting Identification53
Conclusion54
Building the Wing65
Getting Ready65
Preparing the Main Spar65
Assembling the Rear Spar65
Preparing the Wing Ribs66
Assembling the Wing Skeleton66
Main Rib/Spar Assembly66
Fitting the Wing Skins66
Assembling the Fuel Tanks67
Fitting the Attach Angles to the Spar and Rear Tank Baffle67
Fitting the Tank Skins to the Ribs and Rear Baffle67
Final Preparations67
Closing and Finishing the Tank68
Riveting the Wing Skins68
Wing Skin Preparation and Assembly68
Assembling the Wing Leading Edge69
Installing the Leading Edge69
Riveting the Top Skins69
Installing the Aileron Brackets69
Flaps70
Attaching Ailerons to the Wing70
Attaching Flaps to the Wing70
Wing Tip Installation70
Firewall73
Rv-8 Forward Fuselage Floor73
Section : 8 the Fuselage73
Rv-8 Cooling Air Ramp Assembly74
Rv-8A Forward Fuselage Subfloor Assembly74
Rv-8A Cooling Air Ramp Assembly74
Rv-8 Landing Gear Box Assembly74
Rv-8 Forward Fuselage Sub Structure75
Rv-8A Forward Fuselage Sub Structure76
Center Section77
Seat Rib Subassembly78
Longeron Bending80
Rv-8 Fwd Fuselage Structure80
Rv-8A Fwd Fuselage Structure81
MID Fuselage Skins and Structure81
Joining the Rv-8 Fwd & MID Fuselage Subassemblies82
Joining the Rv-8A Fwd & MID Fuselage Subassemblies82
Tailcone Bulkheads83
Aft Fuselage Assembly84
Adding Tailcone to Fwd Fuselage84
Drilling Fuselage Skins85
Preparing Fuselage Parts for Final Assembly87
Fuselage Final Assembly89
Skin Riveting90
Note on Battery Location Choices91
Rv-8 Forward Bottom Skins91
Rv-8A Forward Bottom Skins92
Rv-8A Main Landing Gear Mount Installation93
Rv-8 Main Landing Gear and Tailwheel Installation93
Rv-8A Main Landing Gear Insallation94
Rv-8A Step Installation95
Front Seatback95
Rear Seatback95
Seat Floors96
Rv-8 Consoles and Seat Ramp97
Rv-8A Consoles and Seat Ramp98
Empennage Attachment99
Elevator Control System100
Rudder Stops102
Flap Motor102
Rudder Control Cables102
Rudder Pedals102
Fuel System104
Brake System105
Aft Upper Skin and Bulkheads105
Fwd Upper Fuselage106
Baggage Door107
Manual Elevator Trim Cable Installation108
Wing/Fuselage Assembly109
Wing Root and Flap Intersection Fairings110
Installing the Slide Rails113
Preparing the Canopy Frame113
Fitting the C-801 Plexiglas Bubble113
Section 9: Fitting the Canopy113
Fitting the Canopy Skirt114
Installing the Canopy Latch114
Installing Windshield Molding Strip114
Engine Mount117
Installing the Rv-8 Main Gear Axles and Brake Assemblies117
Installing the Rv-8A Main Gear Legs, Wheels and Brakes117
Brake Lines117
Installing Rv-8 Gear Leg Fairings118
Rv-8 Main Wheel Fairings118
Wood Gear Leg Stiffeners on the Rv-8A Main Gear (Optional)119
Installing the Fiberglass Rv-8A Main Gear Leg Fairings119
Installing the Rv-8A Nosewheel120
Setting the Breakout Force of the Nosewheel120
INSTALLING the WHEEL PANT and U-713C SUPPORT BRACKETS120
Installing the Rv-8A Nosegear Leg Fairing120
Rv-8A Main Wheel Fairings121
Intersection Fairings121
Finishing the Wheel Fairings121
Empennage Fairing122
Wing Root Fairings122
Engine and Propeller Selection and Installation125
Recommended Engine Installation Manual125
Installing the Engine Mount to the Fuselage125
Conical Engine Mount Installation125
Oil Pressure Gauge Line126
Fuel Pressure Gauge Line126
Manifold Pressure Line126
Primer System126
Engine Selection127
Propeller Selection127
Disadvantages127
Constant Speed Propellers128
Installing Constant-Speed Propellers129
Installing Fixed Pitch Propellers and Prop Extensions129
Specific Props for Rvs129
Matching the Engine to the Propeller129
Engine Identification130
A Guide to Lycoming Four Cylinder Parallel Valve Engines131
Service Instruction137
Conversion137
Front Mounted Propeller Governor137
Rear Mounted Propeller Governor137
Propeller Governor Oil Line Nut and Elbow138
Typical Engine Plumbing Diagram139
Typical Installation of a Control Cable to the Mixure or Throttle Arm139
Fitting the Cowl, Spinner & Cooling Baffles141
Air Filter Systems141
Before Fitting the Cowl141
Installing the Hinges141
Fitting the Upper Cowl142
Fitting the Lower Cowl142
Modifying the Cowl for the Rv Nosegear Leg143
Installing the Inlet Ducts143
Installing the Oil Filler Door143
Protecting the Interior of the Cowl143
Engine Baffle Installation144
Maximum Baggage Weight155
Aircraft Weighing155
Staying in the Envelope155
Section 14: Weight and Balance155
Rv-8 Weight and Balance Sample Calculations156
Some Examples156
Rv-8/8A Weights and Limits - Easy Reference156
Empty Aircraft156
Rv-8 Weight and Balance Calculations157
Final Inspection and Flight Test161
Pre First Flight161
Inspection and Preparation of the Airframe161
Preparation and Inspection of the Engine162
Inspection (Introspection?) and Preparation of the Pilot162
Pre Flight Planning163
Weather163
Emergency Plans and Procedures163
Selecting the Right Airport163
Perform a Preflight Check164
Other Important Preparations164
Taxi Tests164
That First Flight164
Landing165
Expanding the Envelope165
Post First Flight165
Pertinent Thoughts165
Stability Investigations166
Flight Test Procedure:167
Directional (Yaw) Stability168
Lateral Stability Flight Test168
Stall Testing169
Spin Testing169
GPS Tests for Airspeed Calibration170
Limit Testing171
Flutter Testing171
G-Load Testing171
Maximum G-Load171
Airspeed Indicator Markings172
Aerobatics172
Recording Flight Test Data172
Airspeed Calibration173

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General

Brand	Van's Aircraft
Model	RV-8
Category	Aircrafts
Language	English

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