November 16, 2023:
We launched our first hands-on fabrication and assembly session for the RV-12iS, beginning with small components from Section 6: Vertical Stabilizer. Students worked across multiple stations, gaining practical experience in tool fabrication, component preparation, and subassembly. One station focused on fabricating a custom “wedge tool” to aid in aligning the rivet tool and blind rivets during installation. At another, hinge brackets were separated and deburred using the bandsaw, Scotch-Brite wheel, and belt sanders, then cleco-assembled with their respective bearings and spacers to form the upper and lower rudder hinges. A third station began similar separating, drilling, trimming, and deburring work on the vertical fin rear spar and lower spar caps.

At the end of the session, students received thumb drives containing section plans and supplemental reference materials, along with assigned homework for the next build day. We also reinforced the importance of logging build hours and initialing completed tasks on the plans. To further emphasize safety, students identified and documented the safety concerns most important to them, which were posted on the parts bin as a constant reminder.

December 7, 2023:
After a short break for Thanksgiving, we resumed work on Section 6. One group completed the upper and lower hinge assemblies by riveting bearings, spacers, and hinge brackets together using squeezed rivets. Another group continued match-drilling, deburring, and pre-assembling the rear spar and the left and right upper and lower spar caps with clecos. Holes for flush rivets were machine-countersunk in the front and rear spars and spar caps, followed by installation of nutplates using countersunk-head squeezed rivets. All ribs were deburred, and the spars and ribs were pre-assembled with clecos to verify proper fit.

We were also pleased to host students from TCAT and their instructor, Steve, who shared insights into their A&P program and related career paths. Our students discussed their own experience building toolboxes and how that prepared them for the RV project. Steve concluded with a short presentation on the importance of accurate documentation and best practices to ensure compliance with FAA standards.

December 14, 2023:
The rib-to-spar preassembly from the prior session was disassembled, and students again divided into two groups. Group 1 completed riveting the spar caps to the rear spar. Group 2 began work on the four vertical stabilizer ribs, forming the leading-edge radius and fluting where needed to ensure straightness and proper fit to the skin.

Group 1 then riveted the ribs to the rear spar, while Group 2 removed protective plastic from the stabilizer main and forward skins. The forward skin was final-drilled and dimpled, and the main skin was dimpled and fitted with 18 nutplates. After Group 1 finished the stabilizer skeleton and attached the upper and lower hinge assemblies, the main skin was stretched over the skeleton and preassembled with clecos.

December 21, 2023:
Riveting of the main skin to the skeleton began. For every cleco removed, one pulled rivet was installed. Teams worked in coordinated roles—one student removing clecos, another installing rivets with a pneumatic puller, and two others checking skin alignment to ensure proper installation. Approximately 120 rivets were installed over the course of the day. Students who completed their tasks early began preliminary work on rudder components in preparation for the next session.

We also had the pleasure of meeting Jim, a retired American Airlines pilot visiting the area. He shared how a flight at age nine near Johnson City sparked his lifelong passion for aviation. Jim later took his private pilot check ride with the legendary “Mama Bird,” Evelyn Bryan Johnson, whose tribute stands at the entrance to Morristown Regional Airport—a fitting reminder of aviation’s enduring legacy and inspiration.