It's funny how frustrations somehow work out to be a blessing in disguise. We weren't able to invest much time on the project during May & June due to other obligations and adjusting to a change in work schedule (i.e. back to the commute). As things started to settle down and there was talk of resuming our riveting of the tailcone, there were blurbs online about builders having issues with laser cut parts provided by Van's. This culminated with the following post on Van's website on July 4:
"In early 2022, Van’s began manufacturing some parts via partner contractors utilizing a fiber laser cutting process. This decision was made after completing a formal manufacturing process evaluation and extensive fatigue testing of materials used in the manufacturing process, with the purpose of increasing the production capacity for some parts during a period of high demand. Van’s has recently received reports from builders that cracks have formed in some parts with laser-cut holes while dimpling, or while riveting the dimpled holes. We are acting on those reports and investing time, resources, and energy to address customer concerns and provide answers." Before long, a list of approximately 5 pages worth of parts that could have potentially be laser cut for the RV-10 was shared by Van's outlining which were in each of the various stages of testing. It would seem that we were largely spared on the rudder and vertical stabilizer that we've completed but I still have some verification to perform. Same goes for the horizontal stabilizer. As for the tailcone that is in process, I'm pretty sure that several (if not all) of the bulkheads were laser cut and will need to be replaced. I am almost done reviewing our parts list for the wing and fuselage kit and have identfied dozens of laser cut parts that will need replacement. In the end I'm grateful that we hadn't been hard-charging through the kit over these last couple/few months or we would have had a lot more heartbreak in terms of required disassembly. Based on my inventory, it would seem I'll be able to proceed with the elevators and possibly skip ahead to the ailerons while awaiting further word from Van's.
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