TCW Technologies


RV-10 Products



First Flight video:

Fuel Flow Write-up    See what we learned about fuel pressure and flow in our RV-10 

Step Bushings:

   One of the known issues with the RV-10 is that the entry steps can get loose over time.   I believe part of the root cause of "wiggly step syndrome" is that the bolt that holds the step to the step mount really doesn't have anything substantial to work against when it is tightened.   As you tighten the bolt it just crushes the step tube and bracket, making it oval instead of round.    So here's my solution.   Turn a solid bushing that fits inside the step tube to give the bolts something to work against.   With the bushing pressed inside the tube a real clamping force can be established between the step tube and the step bracket.   The following pictures show the bushing being made and then ready to be pressed into the tube.  NOTE, I drilled the hole in the bushing LARGER than the actual bolt so the bolt would easily pass through without any difficult alignment issues.   This worked very well.  The hole is 1/4",  the bolt is an AN-3.

finished bushing, ready to press in

The Step Bushings are now for sale.   Installation instructions (click here)

$40 a pair plus shipping.    


Fuel Line Fittings:

       There has been discussion regarding the techniques for routing of the fuel lines through the tunnel area and out to the wing tanks.   The Van's procedure has you contort 3/8" aluminum tubing in a series of bends that essential must be made with the tubing down in the tunnel.  When you are done you have a stub of tubing sticking out of the side of the airplane until the wings are attached some day.     Some folks have opted for flexible lines from the fuel selector valve all the way to the fuel tanks.      Others have suggested using AN type bulkhead fittings to pass through the tunnel and then through the fuselage.   The problem with this approach is the pre-punched holes in these places are 1' in diameter.   A bulkhead fitting would fall through this size opening.    

      I liked the idea of using bulkhead fittings so I machined the following bushings to adapt the standard AN bulkhead fittings to the pre-punched holes.


AN833 elbow with bushing

elbow mounted in tunnel

elbow in tunnel, interior view


1 pair of bushings with 2 bulkhead style elbows (AN833-6d) with retaining nuts.   (for use on tunnel pass through only)

Fuel bushings with elbows - 1 pair   $45 plus shipping 

Rear equipment tray for our RV-10.      

I wanted to utilize the area behind the baggage compartment for many of the electronic items we are going to have in the RV-10 that don't need regular attention.  Our aux battery, strobe, elt, safety-trim, a small power bus are going on these platforms.  The goal was to add some mounting platforms that integrated with the existing structure and ideally did not require changing the stock Van's battery shelf /elevator bell-crank mounting platform.

The design utilizes two simple aluminum pieces that we bent up from 0.063 sheet stock. See PDF below for dimensions.  The design allowed for a simple trapezoid shaped part with just two bends.   I cut the material on a  table saw (with a proper metal cutting blade) and bent the two stiffening angles in a box/pan brake.  The trays are bolted and riveted to the existing stock Van's battery tray.   I wanted to utilize the J channel side stiffeners which support the outer skin to also support the two trays.   To do this I cut the j-channel  just behind the end of the tray, with a pair of tin snips and unrolled the j portion to form a shelf.  I drilled a hole first though to prevent a stress crack from forming at the cut location in the j channel.  The only real issue is that this j channel is not in the same plane as battery tray.  This requires two spacers on each side to support the tray in the same plane as the stock battery tray.  The spacers are made from 1/2" diameter phenolic with a #19 hole drilled in them.  The longer spacer is 11/16" long.  The shorter spacer is 3/8" long.      I added 3  -  K1000-08 nut plates along the un-rolled j channel to fasten the new trays to outside walls of the airplane.   The following pdf drawing is of one of the trays, the other is a mirror image.    The holes drilled in the outside edge are about 4.5" apart.    The connection to the stock battery tray piece is made with 2 bolts and 3  AN470-4-5 flush rivets per side.   The bolts replace the existing rivets that normally fasten the stock battery stop brackets to the stock battery tray. See photos below.

Click on a picture to view full size.

top view of trays

bottom of trays

trays attached to bottom of stock battery support

j channel un-rolled, for tray mounting

Tray spacers. 1/2" diameter phenolic

Bottom view of trays and stock center piece joined together

note 2 bolts on each tray replace stock rivets, front and rear

Completed equipment tray

tray with equipment

tray with equipment

Tray with equipment added

Equipment Tray Drawing (click to download a copy)


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Last modified 2/8/2018

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