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It’s been seven weeks since we made the exhilarating decision to purchase our RV-9A kit. Since then, we’ve been in full swing getting our hangar ready for the kit’s arrival. We’ve rearranged our space, planned out part storage, bought essential tools, and even built workbenches. It’s been a whirlwind, but an exciting one.
Rearranging Our Hangar
On New Year’s Eve 2023, we were lucky to get a call about a hangar just 10 minutes from home. Not only was it close, but it also faced the sunset and was right next door to our best friends. This hangar quickly became our home away from home and the resting place of our Cessna 150. Over time, we’ve added creature comforts like a soft couch, fridges, and tables to make it a cozy spot for both work and relaxation. It also doubles as storage space for tools and hardware for Sam’s business.
When it came time to make room for our RV-9A workshop, we initially moved the plane to one side of the hangar and set up a work zone on the far side. In theory, this seemed great, but in practice, it felt cramped. Walking in the man door was tight, and getting around the plane to reach the work zone was a challenge. So, we swapped sides, and eureka! The new setup worked perfectly. We now have Sam’s business equipment stored on the narrow side, a “clean desk” area for plans and research in our comfy zone, and a spacious workshop in the back quarter for storage and manufacturing.
Tools
Tools
Sam put in meticulous research and consulted with our EAA group of experienced Vans builders. Their advice was invaluable. They guided us on which tools to buy, recommended used tools, and even offered to loan us some of theirs. After much deliberation, we ordered a tool kit specifically for the RV-9A build and decided to splurge on the DTRT-2 dimpler—a worthwhile investment when you think of the 15,000+ rivets.
Storage
Storage
Ah, the age-old dilemma: storage. How do you store tools? How do you store parts? Luckily, the hangar came with a small, well-loved toolbox on wheels. While it’s missing a drawer, it’s served us well for storing our aviation tools so far. However, we knew we’d need more as we acquired new tools and accessories. We decided on a metal shelf on wheels with bins and totes to organize everything efficiently.
Storing parts presented a bigger challenge. We opted for a set of four shelves to inventory our kit plane. When the shelves arrived (each box weighing 85 pounds), Sam was out of town. Despite their weight, I managed. However the next day, after reading reviews, Sam decided to go with shelving he already uses in his woodworking shop. Together, we built, arranged, and developed a system to organize and catalog the parts for easy access.
Workbenches
Workbenches
Building the workbenches was a blast! If I ever doubted that we were a great team, this project proved it. We quickly streamlined the process and built four identical benches. Each of us tackled specific tasks, and the workflow couldn’t have been smoother.
A lesson I learned during this project is to double-check my answers, especially on something as critical as building a plane. I have a tendency to agree without fully verifying, but I’ll be much more diligent moving forward. Big shoutout to Sam for running to the store for wood glue—which turned out to be essential for more than just “decorative” molding.
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