Airplane factory / shop build

[gtae07]

Airplane factory / shop build (Completed!) Now airplane build

Background:
About two years ago I started building an RV-7 in our one-car garage (strike one). I got increasingly frustrated with the tiny workspace, which had to hold a wing jig, workbench, and storage shelving, plus all of my other miscellaneous (car and wood) tools, the bikes, etc. I kept wishing I had a detached shop or a larger garage, and swore that I wouldn't let that get missed on my next house.

Then one day my wife suggested "well, why don't you build one here?" (Oh, how I love that woman... little did she know what she was starting )

At first I dismissed the idea as impossible; we live on 1/5th of an acre (strike two) in an HOA-controlled community (strike three). But then I pulled out the city code and the HOA rules, and to my surprise found that there was nothing prohibiting it on our lot, provided I held to a few restrictions on height and construction.

So the planning and drawing started. Surveyed the lot, drew everything in CAD, negotiated terms with the wife, put a budget and schedule together, and submitted the paperwork for approval. The city didn't care and approved immediately; it sat in the HOA's inbox for a month before a polite inquiry pushed it through at the end of October.

Of course, immediately following the approval, I was offered a new job, DST ended for the winter, and my wife's medical condition flared up. Oh, and it rained... and rained... and rained... and rained some more on the weekends. Construction started three months later than the original plan, and the site prep and foundation work that was supposed to take three weeks took three months thanks to the weather, holidays, and other factors.

The shop itself:
The shop will be 28 x 24 x 8; sizing was driven by HOA restrictions on height, a desire to be able to temporarily fit both wings on the airplane for finishing work, and the largest size I could get my wife to buy off on. I'm using 2x6s at 24" OC, rafters at 4:12, balloon gable walls, and a mono slab, all built to hurricane wind standards for the area. I have two 8 x 7 roll-up doors on one of the long sides (the largest I could do within the prescriptive hurricane codes without needing an engineer’s stamp, and I’m not the right kind of engineer), and a man door on the short wall facing the house. I’m planning on full insulation and (eventually?) air conditioning, preferably with a mini-split heat pump.
Electrically, I want outlets everywhere (including a couple on the ceiling for pull-down cord reels) and a few 240 outlets for the welder, large compressor, mill, lathe, etc. I’ll eventually acquire. Hard-line air supply is also in the plans.

Long-term, once I’m moved into the shop, I’ll be converting the garage into an art studio for the wife, adding a painting table and easel, some storage, a utility sink, and more insulation.

Current status (3/12/15):
Concrete was poured last week, and weather permitting I’ll start pulling the forms off this weekend. Lumber will hopefully be delivered next week and I’ll get started on framing.

(pictures to follow)

 

[Terranova]

Sounds like you have the plan locked down! Good luck on the build. As you've already figured out, expect the unexpected.

T

 

[Capt Chrysler]

gtae07, YOU KNOW THE RULES!

No Photos, or it didn't happen!

Capt. Chrysler

 

[longez]

Having built 5 planes (2 LongEZ, 1 Glassair, 1 PJ-260, and 1 RV-4) I can say your current delays, and others TBD, will all be a part of the monumental task of building your own flying machine. A nice shop is helpful, but I've had wings behind the sofa and Lycomings stored on the washing machine while the Mrs went to the laundromat. Slow and steady my friend.

My advice: keep mamma happy

 

[gtae07]

gtae07, YOU KNOW THE RULES!

No Photos, or it didn't happen!

Capt. Chrysler

Sorry, can't post photos at work It'll have to wait till I get home tonight.

Having built 5 planes (2 LongEZ, 1 Glassair, 1 PJ-260, and 1 RV-4) I can say your current delays, and others TBD, will all be a part of the monumental task of building your own flying machine. A nice shop is helpful, but I've had wings behind the sofa and Lycomings stored on the washing machine while the Mrs went to the laundromat. Slow and steady my friend.

My advice: keep mamma happy

This isn't my first build; my dad and I built an RV-6 while I was in high school and he gave me most of his airplane-specific tools when I started my -7. Right now half the empennage is hanging on my garage walls, and the rest is up in an unused bedroom. That was part of the deal--all the airplane stuff goes in the shop, and she gets full run of the house plus her own art studio.

I was just getting really tired of having to spend 5-10 minutes moving things out of the way every time I wanted to go work on the plane or do anything else out there. This shop will have enough room for me to do just about everything before I move to the airport (I want to minimize traveled work). Also, it's going to be well-used even after the RV is done.

 

[StevenMorgan]

As another airplane builder, I gotta say, vault the ceiling if possible. Tail feathers attached while on a rotisserie gets big quick. Or when the whole thing stands up on its nose (like I did to my Super Decathlon when I used the engine mount to pull myself up from underneath and it came over on me!) It also makes great long term storage of all the items longez was hiding in his house! Maybe work in a whole wall storage system.

I'm building my garage right now too, and I am pencilling in a "poor-mans" downdraft paint booth with windows for fresh air high on one wall, and the garage door cracked on the opposite wall. A plastic tent around my project and a few furnace filters & box fans will go a long way.

 

[LS6 Tommy]

I'm not an airplane builder, but I know somene who built one in his garage. Don't make his mistake- attach the wings AFTER you roll it out of the garage.

Tommy

 

[gtae07]

I'm not an airplane builder, but I know somene who built one in his garage. Don't make his mistake- attach the wings AFTER you roll it out of the garage.

Tommy

The final/permanent attachment will happen at the airport. At home I can use temporary hardware for test-fitting (they bolt on) and to hold them on temporarily for wiring, fabricating fuel connections, trimming access covers, etc. and then take them off.

We didn't do that on my dad's airplane; it moved to the airport earlier and it really slows down the last stages of the build when you can't just walk outside and work on it. And that was with the local airport only 10 minutes away; I'm most likely going to be using one that's 30-40 minutes away so I have a lot of incentive to maximize the work done at home.

 

[gtae07]

The evening of the pour:

The plan:

 

[R7237]

very nice. Finishing my RV-7 hopefully in a few years. Hangar at KOKZ. You should really make a trip to talk to Ray Lawrence (airport manager). He has built probably 17 of them by now. Very knowledgable guy and will save you a lot of heartache in the process.

 

[Chevy72pu]

very nice. Finishing my RV-7 hopefully in a few years. Hangar at KOKZ. You should really make a trip to talk to Ray Lawrence (airport manager). He has built probably 17 of them by now. Very knowledgable guy and will save you a lot of heartache in the process.

Would Ray be from Sandersville? If so I know him and his dad. J Brooker from Sandersville has also built his own plane.

 

[Jackfre]

Just poured sthe footings on my 30x34x10. Kinda thinking an RV12 would be good in there. Would like to do a 14, but at 66, I'll be lucky to finish the 12. My wife, a very sweet and patient girl, thinks she is going to park a car in there

 

[Badhabit]

This may just be the way it is on the drawing. The sheets of wood on the exterior should be horizontal rather than vertical. That way each sheet picks up more studs and the top layer can be staggered, making it stronger yet
H

 

[gtae07]

This may just be the way it is on the drawing. The sheets of wood on the exterior should be horizontal rather than vertical. That way each sheet picks up more studs and the top layer can be staggered, making it stronger yet
H

I'm deliberately going vertical with the sheathing for a couple reasons.

First, the hurricane wind manuals prefer the vertical orientation for uplift and shear resistance.

Second, vertical means I only need blocking on the end walls (where I'd need a firestop anyways).

 

[kbs2244]

Too bad it is an RV.
You are going to learn a lot about wood construction.

 

[gtae07]

Two steps forward, one step back...

Update 3/30/15:

Sill plates are bolted in temporarily and I've taken measurements for adjusting stud height. All the lumber has arrived and has been staged for construction. Weather permitting, I can unbolt the sills and maybe start nailing walls together tonight or tomorrow night.

HOWEVER

I'm afraid I might have made a design (and ordering) error . At least, somewhere along the line I seem to have specified 24' 2x8s for my ceiling joists. I would have been ok with a 16" spacing but not at 24". I'm trying to figure out what the best solution will be... but I'm afraid it's going to be "order 24' 2x10s".

If that's the case, any suggestions on what to do with 13 24' 2x8s?

 

[Zeke]

The lumber people normally take the lumber back. I'd be surprised that you can't negotiate something. You'll need a way to load it back on their truck be it a forklift or 3 of your best friends plus wife.

This may just be the way it is on the drawing. The sheets of wood on the exterior should be horizontal rather than vertical. That way each sheet picks up more studs and the top layer can be staggered, making it stronger yet
H

That's actually wrong. The sheets for earthquake and hurricane need to capture the bottom plate and the top plate in the same sheet. We use 3 x lumber at the bottom and a double top with staggered nailing, sometimes 3" O.C. at the top and bottom. If the wall is over 8' we are allowed to put in 3" continuous blocking at the joint. The next panel over is staggered up and the blocking installed low. And so on. Makes you get your stud layout spot on. We even have to in some cases use 3 x studs at the 4' line and occasionally a 4 X post near a hold down. A framed wall around here can look pretty odd before sheathing.

 

[Kirmet]

Where's the RV build thread?

I have an Aeronca Chief I started to restore but stalled since I can't sand, grind, paint, in my basement garage. Not to mention I got ripped off on the wood spars which further sapped all my mojo.

 

[gtae07]

The lumber people normally take the lumber back. I'd be surprised that you can't negotiate something. You'll need a way to load it back on their truck be it a forklift or 3 of your best friends plus wife.

Phone call this afternoon indicates they'll be willing to deal. Just have to work it out.

Where's the RV build thread?

I have an Aeronca Chief I started to restore but stalled since I can't sand, grind, paint, in my basement garage. Not to mention I got ripped off on the wood spars which further sapped all my mojo.

No build thread anywhere... but once the shop's done and I've moved in, one will probably follow.


Got a bit of time after work, started framing

 

[gtae07]

As of Saturday evening:

And starting the electrical layout:

Squares are 240 with amperage; circles are 120 labeled by circuit (O is outdoor, C is ceiling for dropdown cord reels). Lights run in three banks. Breaker panel in bottom left corner.

 

[gilr]

I'm building an RV-12 in a 24' x 24' garage with a friend and it works fine. We just installed the engine this past weekend and there is still clearance to walk around it without the prop and spinner installed. Half of the battle is having heat and air conditioning which enables you to be more productive. If you were building in a hangar without heat or air, life would be miserable to say the least. We have built and stored the wings until we get to the airport for final fitting and testing so that hasn't been an issue with space and enabled us to work in this size garage. The RV-12 is designed to have the wings removable, but once they are fitted the final time they are staying in place. This has been an enjoyable experience for us, but certainly different than building cars/street rods of which I have built quite a few. The prep work is half the effort but certainly necessary.

Good luck on your build and then on to building your 7.

 

[gtae07]

As of Tuesday evening:

Progress to resume tomorrow afternoon as I've been sick for a day or two.

 

[gtae07]

Major progress this weekend; the ceiling joists are in. Next step is some more hurricane straps and clips, then sheathing the walls, then ridge board and rafters.



I'm quite proud of my method of raising the ceiling joists--those MF'ers are heavy and awkward. Wasn't sure how I was going to do it (much less do it myself) till I had a brilliant idea at work.

I made angle braces to sit on the top plate and capture the end to keep it from tipping over till I tied it to the top plate and the attic bracing. The side with two braces is the side without the big doors. The ladder is positioned as an intermediate point so I don't have to do the whole lift at once.


Joist is in the far end; next is the lift to the ladder (with hard hat on)


On the ladder now, and ready to go onto the top plate (I lost that picture)


The job site foreman approves:


Burned a few brownie points with the wife this weekend, but I'll get them back.

 

[gtae07]

No progress last weekend; out of town visiting our mothers.

This weekend, a good bit got done. It was the first time I've had help at all, other than the guys I paid to pour and finish the concrete. We set 27 of 30 rafters; the others I'm leaving out for the moment so I can get on the attic deck easier.

On the not-so-bright side, I got a festering spider bite on my leg for my troubles. Dropped in on urgent care this evening; got two shots in the *** and a double RX of Keflex for my trouble.

 

[Strouty]

Looking good, I bet you are excited to have it start looking like a building! Sounds like the spider bite got you in the end.

 

[gtae07]

Looking good, I bet you are excited to have it start looking like a building! Sounds like the spider bite got you in the end.

Yeah, walking around inside makes it a little more real. I'm hoping two more weeks and I'll be ready for the nailing inspection; then I'm hiring out the roofing and hopefully the siding--it'll take forever if I have to do it myself, and the city won't buy off electrical till everything's dried in. And I want to get all my stuff moved out of the garage so I can fix that up for its new purpose. I also may have promised the wife a weekend or two of my undivided attention...

 

[gtae07]

Big progress--nailing inspection Tuesday, and by Wednesday evening I had a roof! Started wrapping today after work; aiming to get door and window in this weekend and trim out the garage doors in the week after. Then, siding.

 

[rarebreed]

Looks good. You are doing this all yourself?

 

[rixtrix1]

Good luck with the garage and RV build. Best friend just bought an RV-6 that the original owner/builder flipped during first taxi. Sold it to a restoration guy who added an RV-7 tail assy and converted it to taildragger. All repairs made using factory parts. Needs a little interior work to cover some metal and spruce it up. I'll be flying with him in a month to our 45th class reunion, so I'll get to check it out. Another friend's dad just built an RV-12. She won't fly with him because, in her words," It's made with pop rivets!" lol

 

[bczygan]

Nice build and all......But where's the photos of the RV-7?

 

[gtae07]

Looks good. You are doing this all yourself?

Mostly. I had a crew pump and finish the concrete, I hired out the roof (shingles etc) and got help from friends one weekend for part of the roof structure. I'll also probably be hiring out the siding, in the interest of marital peace But all the rest of it, I've worked myself.

Another friend's dad just built an RV-12. She won't fly with him because, in her words," It's made with pop rivets!" lol

Absolutely nothing wrong with blind rivets if they're accounted for in the design. They aren't hardware store pop rivets, but aviation quality hardware.

Nice build and all......But where's the photos of the RV-7?

Sitting on our server. I'll get around to posting them once the shop is done and I'm working on it again.

 

[Mpower5266]

Judging by your location, my job, and the type of plane you are building, we have probably met. Or at least spoken on the phone. I cant wait to see more pics of the build and the rv.

 

[Okietools1]

This is a cool build. Love to see it when it's done.

 

[j p smith]

Good luck with the garage and RV build. Best friend just bought an RV-6 that the original owner/builder flipped during first taxi. Sold it to a restoration guy who added an RV-7 tail assy and converted it to taildragger. All repairs made using factory parts. Needs a little interior work to cover some metal and spruce it up. I'll be flying with him in a month to our 45th class reunion, so I'll get to check it out. Another friend's dad just built an RV-12. She won't fly with him because, in her words," It's made with pop rivets!" lol

rixtrix1. Any leftover parts, I am looking for the tail assy of a small plane for a project. broken or bent up is fine

 

[Bib Overalls]

If you can build a shop/garage then putting an airplane together should be a snap.

 

[gtae07]

Exterior is effectively complete; now running wires and getting ready to pull the MHF through the conduit (it arrived yesterday). Still need to bust up the concrete lumps and get them out of the way and start fixing the landscaping. Also waiting on word from the inspector on how far I can go with the electrical before he has to inspect; I hope the answer is "hook it all up and just don't turn it on".

A couple more weeks, and I can put the top skin on the other wing and move everything in.

 

[gtae07]

One wire left to terminate for the future AC install. After that, I'll clean up the mess and do the electrical inspection. Then insulation, drywall, and maybe grinding the floor a bit followed by a densifier.

My goal is to be moved in before the wife and I go to Seattle in a month. Then we come home and I fix the garage up for her, and we see how much a landscaping company will cost (we're both black thumbs--we killed basil).

 

[sublime68charger]

Nice work bet your just itching to get to work on the rv-7 out there.

 

[gtae07]

Nice work bet your just itching to get to work on the rv-7 out there.

Yeah, I can't wait. I'm so close....

Unfortunately we discovered last night that we're going to have to tear up part of our bathroom. Looks like the airplane's on hold for another month or three

 

[gtae07]

And the power's on! Had a small problem with one circuit at the GFCI outlet (actually the very first outlet and wires I installed), so I have to fix that, but all the rest of the 120 works fine.

Insulation's on order and then drywall.

Then, finally... move-in day!