SECTION 8
THE FUSELAGE
RV-8/8A
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8s8PP-1 r1 06/23/11
DWG 82 or “Left Side Iso View”, DWG 82A).
Install the fuel bulkhead fitting in the firewall (See “Iso View Fuel Injected System” or “Iso View Carbureted Sys-
tem”, DWG 82).
Make and install the fuel line that runs between the fuel filter and the fuel pump.
Note: The line needs to be
made in place.
First complete the flare on the aft end of the line, slip the line through the snap bushings (RV-
8) and connect it to the fuel filter. Mark the fwd end of the line for trimming to proper length. Disconnect the
line from the fuel filter and slide it forward to complete the flare on the forward end.
Make and install the fuel line between the fuel pump and the bulkhead fitting on the firewall.
Fuel injected System Only:
Make and install the fuel return line between the Airflow Performance fuel pump
and the fitting on the bottom of the fuel valve following the same process used for the previous fuel pump line
(See “Detail A” and “Iso View Fuel Injected System”, DWG 82).
BRAKE SYSTEM
NOTE: The brake systems on the RV-8 and RV-8A are similar. Because of this, the RV-8 Brake System
DWG 83 will be used as the primary reference for both models. DWG 82A will be used for detailing the dif-
ferences for an RV-8A.
Install the VA-107 Brake Fluid Reservoir on the Firewall Assembly using the hardware depicted (See “Isometric
View”, DWG 83).
RV-8 Only:
Install the brake line fittings through the F-822-1 Fwd Floor Panel, inside each of the L.G. Box As-
semblies (See “Front View” and “Isometric View”, DWG 83).
NOTE: An AN960 washer is required as a
spacer on each fitting.
RV-8A Only:
Install the brake line fittings through the hole in the bottom plate of the WD-821-1 Landing Gear
Weldments (See “Bottom Iso View”, DWG 82A).
Install the two brake line fittings in the F-866D Mounting Plate (Detail A, DWG 83). Orient them as shown in
“Front View”, DWG 83.
Make the Left and Right Brake Lines (See DWG 83 or 82A). Connect them to the fittings at each end and
clamp them to the F-802E-L-1 & -R-1 L.G. Box Web (RV-8) or the aft side of the F-802R-L-1 & -R-1 Fuselage
Bulkheads (RV-8A).
Install the two F-8105 Brake Hoses (DWG 83).
Install the Male Nylon Tee on the VA-107 Brake Fluid Reservoir using thread sealant.
Install the two reservoir lines between the Brake Fluid Reservoir (See “F 271-N-04X02 Male Nylon Tee Assem-
bly”, DWG 83) and the fittings on the top of each Brake Master Cylinder (See “F 69-F-04X02 Brass Elbow As-
sembly”, DWG 83). The brass nut on the master cylinder fittings must be tightened very firmly to compress the
brass sleeve around the tube.
If installing the optional Van’s Aircraft Static System Kit, do so now before riveting on the aft upper skin.
Refer to the Static Source view on DWG 85 and the documentation supplied with the Static System Kit
.
AFT UPPER SKIN AND BULKHEADS
Make plywood backboards as shown in “Backboards”, DWG 85 to provide a work platform to lay on when work-
ing inside the tail cone.
Deburr the F-807B-1, F-808B-1, F-809B-1, and F-810A-1 Bulkheads.
Final-Drill #40 the 3/32 rivet holes used for attaching the two nutplates to the F-808B-1 Bulkhead (See “F-808-1
Bulkhead Assembly”, DWG 71).
Cleco the F-807B-1, F-808B-1, and F-809B-1 Bulkheads to their respective bulkhead assemblies (See DWG 70
and 71).
RV-8/8A
SECTION 8
THE FUSELAGE
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Final-Drill #30 the 1/8 holes common between the F-807B-1, F-808B-1, and F-809B-1 Bulkheads and their re-
spective bulkhead assemblies
Deburr the edges of the F-869-L-1 & -R-1 Bulkhead Gussets (See “Detail A”, DWG 71).
If desired, tie down ring stowage is available behind the rear seat as shown in “Detail A”, DWG 71. Make two
homemade nutplates by welding a 3/8-16 nut to a small steel plate that has a 3/8-inch hole drilled in the center.
Then drill and rivet the homemade nutplates to the F-869-1 Bulkhead Gussets. An alternate method is to use a
small aluminum block approximately 3/8 thick, drilled 5/16 and then tapped 3/8-16.
Cleco the F-869-L-1 & -R-1 Bulkhead Gussets to the F-807 Bulkhead Assembly (See “Detail A”, DWG 71).
Cleco the F-810A-1 Bulkhead to the forward flange of the F-819-1 Aft Deck (See “Detail E”, DWG 71). Final-
Drill #30 the 1/8 holes common between the bulkhead and the aft deck.
If using manual elevator trim, final-drill 5/8 the left 3/16 tooling hole in the F-810A-1 Bulkhead for a bushing
(See “Detail E”, DWG 71).
Deburr the edges of the F-882-1 Canopy Rail Receptacle. Cleco the canopy rail receptacle to the aft side of the
F-807B-1 Bulkhead (See “Detail B”, DWG 71). Final-Drill #40 the 3/32 holes common between the bulkhead
and the canopy rail receptacle.
Smooth and deburr the edges of the F-825-1 Aft Top Skin.
Cleco the F-825-1 Aft Top Skin in place on the aft fuselage.
Position the outboard edges of the F-869-L-1 & -R-1 Bulkhead Gussets so they are parallel with the edge of the
F-887-L-1 & -R-1 Upper Longerons and clamp in place.
Smooth and deburr the edges of the two F-858-1 Shoulder Harness Anchors (F-858-1 Shoulder Harness An-
chor view, DWG 71).
Straighten any curvature in the F-858-1 Shoulder Harness Anchors so they lay flat against the inside surface of
the F-825-1 Aft Top Skin.
Modify the aft end of the two F-858-1 Shoulder Harness Anchors as depicted in “F-858-1 Shoulder Harness
Anchor”, DWG 71. File the aft end of the shoulder harness anchors to a reduced thickness so the aft portion
overlaps the flange of the F-808 Bulkhead Assembly. The top surfaces of the shoulder harness anchor and
flange are to be flush with the F-825-1 Aft Top Skin.
Cleco the two F-858-1 Shoulder Harness Anchors in place on the bottom of the F-825-1 Aft Top Skin.
Final-Drill #30 the 1/8 holes common between the F-825-1 Aft Top Skin and the two F-858-1 Shoulder Harness
Anchors.
Final-Drill #40 the 3/32 holes common between the F-825-1 Aft Top Skin and the F-807B-1, F-808B-1, F-809B-
1, and F-810A-1 Bulkheads, and the F-882-1 Canopy Rail Receptacle.
Uncleco and remove the F-858-1 Shoulder Harness Anchors and the F-825-1 Aft Top Skin.
Final-Drill #40 the 3/32 holes along the edges of the F-825-1 Aft Top Skin that are common with the F-824-L-1
& -R-1 Aft Fuse Side Skins and the F-887-L-1 & -R-1 Upper Longerons.
Drill #30 the holes common between the F-869-L-1 & -R-1 Bulkhead Gussets and the F-807B-1 Bulkhead.
Uncleco and remove the F-882-1 Canopy Rail Receptacle, the F-807B-1, F-808B-1, F-809B-1, and F-810A-1
Bulkheads, and the F-869-L-1 & -R-1 Bulkhead Gussets.
Deburr all final-drilled holes in the parts from the previous two steps.
Deburr the #30 holes in the F-887-L-1 & -R-1 Upper Longerons that were match drilled from the F-869-L-1 & -R-
1 Bulkhead Gussets.
Apply a slight bend to the side edges of the F-825-1 Aft Top Skin (See “LAP JOINTS”, Section 5K of the con-
struction manual).
Dimple countersink all #30 and #40 holes in the F-825-1 Aft Top Skin for flush rivets on the exterior surface.
Dimple countersink, flush fwd side, the #40 holes in the web of the F-807B-1 Bulkhead that are common with
the holes in the F-882-1 Canopy Rail Receptacle. Dimple countersink the #30 holes in the F-807B-1 Bulkhead
that are common with holes in the F-869-L-1 & -R-1 Bulkhead Gussets for flush heads on the forward side.
