The RV-15 Build: Assembly Starts and First Impressions

Clear diagrams, tasks broken into very small chunks, and step-by-step instructions formed the first impressions when I sat down to read the RV-15 wing kit instructions. There is no “builder’s manual” or blueprints, at least at this time. There are no detailed drawings with dimensions shown. Instead, there are KAIs, “kit assembly instructions,” suggesting that one is merely assembling IKEA furniture and not building an airplane. KAIs are broken into “Sections” that work with the subkits packaged at the factory. Each page shows a task or small group of tasks to be accomplished. What a contrast to my previous RV-3B build, where about all that the crates contained were drawings with most dimensions and angles shown along with sheets of aluminum, blank stock of angles, and other needed materials. This will be a very different experience.

So, is this an IKEA experience? Perhaps by comparison to earlier kits, but much more than assembly is required. The RV-15 wing kit includes the conveniences of:

• Full-size, perfectly matched holes already drilled.
• Nearly all pieces cut to exact size with all cuts within pieces already made. No more awkward cuts of oblong inspection holes within sheets. (So far, I did have to cut two unnecessary tabs off one piece, following Van’s instructions. I don’t know why but perhaps checking a box in the 51% rule.)
• Pre-dimpled holes in the sheets of aluminum that will fit flush rivets. (Other holes that will require countersinking will need to be done by the assembler/builder.)
• Sheet metal bends, like on the leading edge, that are already made.
• Wing wiring harnesses made to the correct length and bundled. Connectors are included and installed.
• Pitot and static air lines cut to the correct length. Connectors at each end are included.
• Parts organized by subkits that match the KAI sections.

All these features will make construction of the wings fast and relatively easy, if you want to construct a clone of Van’s design (which is currently what I intend to do). But, if one wants the landing and taxi lights in a different place (e.g., on the wingtips) or to build daytime-only without lights, there are already holes cut in the leading edge for lights. In addition, there is also what would be an unnecessary wiring harness. Other desired changes might also be complicated by the advanced stage of development of this kit. But, if what Van’s is offering is what the buyer wants, it will certainly make things much easier and quicker to build.

There has been much talk about the RV-15 being an “all pulled rivets” airplane. While looking at the RV-15 at AirVenture the last two summers showed only pulled rivets on the outside, the assembler who believes this rumor will be surprised by the reality. I didn’t count, but it has felt like most of the rivets used on the wings prior to covering with the skins are solid rivets. Many are easily squeezed solo, but some had to be shot and some even require a second person to buck.

The biggest time sink with the RV-15 wing kit is part preparation. You still must remove the sheets of blue plastic, deburr the edges, and scuff and prime as you see fit (I am only priming the non-alclad surfaces). The holes are so nicely done that the factory says no deburring is needed. However, one side of each hole has a tiny bit of roughness, and I’ve gotten into the habit of running my finger over each hole and doing a very light deburring where I thought appropriate. Generally, on the thicker pieces.

One of the very cool things about the organization of the KAIs is that most pages can be accomplished in a single work session, at least once all pieces are prepped. Each page has limited tasks, so the feeling of tangible accomplishments comes rapidly. I’ve occasionally completed six, seven, and even more pages in a single session working alone. I have fallen into the habit of spending a day, or at least a few hours, prepping upcoming pieces before I start a “Section.” As removing the plastic covering is clean work, I do lots of peeling when I only have 15 minutes to spend in the shop before going out. It is important to re-label each piece with a Sharpie. I leave the dirtier tasks of deburring and priming to shop clothes. Once the pieces are prepped, the boxes are rapidly checked off and the KAI pages fly by.

The RV-15 wing kits come with completed wing tanks. The tanks are built and tested at the factory, allowing the assembler/builder to avoid what some would call “the horrors of Pro-Seal.” Because a significant number of early adopters wanted to modify their fuel tanks to accommodate diesel fuel, Van’s made the decision to allow purchasers to opt out of buying the pre-built tanks and to save $500. I, however, gladly stuck with the default option of pre-built tanks.

The initial assembly/build went so fast that I had 14 feet of workbench covered by the skeleton of the port wing, including fuel tank, in seven days. This sucker is going to require a lot of room! Where will I build the starboard wing?

Van’s tells you that you can build the two wings concurrently or sequentially. At first, I thought the idea of building the wings concurrently was crazy. We have a large shop and a large workbench, but how could two wings be accommodated? Then I realized that it would be very easy and a quick victory to build the second wing prior to installing the tank by interleaving the ribs. This approach went super-fast as I knew how to do it and I just needed to make the starboard skeleton a mirror image of the port. Where to store this somewhat flimsy structure? It fit in the large crate that the wing kit was delivered in.

As I write, I am less than a month into my RV-15 build. I have been spending about 25–30 hours a week in the shop and another 10 hours reviewing KAIs, writing up my progress on Vansairforce.net and here, and corresponding with other early adopters and the factory. Yet, despite this part-time schedule, the following is completed:

• Skeletons of both wings are completed.
• Fuel tank and aileron pushrods are installed on the port wing.
• Main spar, leading edge ribs, wiring harness, and static and port air lines are installed on the port wing.
• A few other pieces are completed for the starboard wing and in storage.
• Work has started on the port wing skins.

It is not an IKEA project, but the very high quality of the components and baby-steps approach of the KAIs sure make the project fun and satisfying. I wake up each morning anxiously waiting for the shop to warm up enough to continue work.