SECTION 03: Tools

Before You Start

Build Instruction Updates

• The current Section 3 is Rev 4 and can be found here.
  • Rev 4 does not incorporate the RV-15 as of yet.
• Van's website also lists recommended tools.

Videos

• Building a Van's RV-15, A Short Primer on Tools — BackcountryRV-15

Workspace

• Wings require a 14-ft bench minimum — ~20 ft total recommended. Use shipping crates as additional work surfaces.
• A 36" wide bench is excellent for mirror-image work
• Build wing and tail stands from the shipping crate foam and wood — available at no cost and sized correctly.

Tools specifically listed in KAI Empannage Sections 6-9 and Wing Sections 20-38.

Hand Tools

• Bench Vise (with soft jaws or soft jaw inserts)
• Bucking Bar
• Crowfoot Wrench (9/16")
• Deburring Tool
• Edge Breaking Tool
• Fluting Pliers
• Hammer or Mallet
• Hand Pump
• Open-End Wrench (5/16")
• Plastic Razor Blade
• Rivet Gun (pneumatic)
• Rivet Puller (pull riveter for LP-4 / MSP / Cherrymax)
• Rivet Squeezer [flush head set and universal head set]
• Screwdriver [Phillips]
• Snips
• Sockets and Wrenches (7/32", 1/4", 9/32", 5/16", 3/8", 7/16", 1/2")
• Straight Flute Reamer (#12)
• Torque Wrench [in-lbs range]
• V-Block / Drill Press
• Washer Wrench (called out in Section 08 — Horizontal Stabilizer)

Drill Bits

• #12, #19, #30, 1/4"

100° Countersink Cutters (Piloted)

• #12, #19, #30, #40 — all at 100°

Dimple Dies

• 3/32" Dimple Die Set

Clecos

• 3/32"
  • Sections 34 & 36 Call for 3/32" clecos with wrong part number (CL316)
• 1/8"
• 1/8" Long Reach
  • Van's P/N TOOL CL18XL (called out in Sections 13 and 14 (fuel tank assembly) and Section 29 (D-Cell Nose Ribs))

Measuring & Inspection

• Multimeter
• Torque Seal, Cross-Check Type — any bright color (yellow or orange are popular for visibility against aluminum)

Consumables

• Avgas — for fuel tank leak testing
• B2 Fuel Tank Sealant — Section 21 (Fuel Sender Assembly) and Section 36 (Flap) for all builders; slow-build tank builders also need it for Sections 11-20 (see Part C)
• Balloon — for fuel tank pressure/leak testing
• CA Glue (cyanoacrylate / super glue) — Section 31 (Skins); used to temporarily tack parts or stabilize drilled holes, NOT as structural adhesive
• Double-Sided Adhesive — Section 38 (Lens and Hatch Covers)
• Duct Tape — Section 31 (Skins)
• Scotch Brite Pad — Section 36 (Flap)
• Tape (general)
• 3M Polyurethane Protective Tape 8672 — Section 32 (Aileron and Flap Cove Skins)

Additional Tools listed in KAI Fuel Tank (non-Quick Build) sections 10-20

Consumables — Fuel Tank Specific

• Acetone — Sections 10-19 (all tank sections); used to clean all surfaces before applying fuel tank sealant. Not called out in non-tank sections in this review.
• Fuel Tank Sealant (B2) — Sections 11-20; required throughout slow-build tank construction. QB builders still need a small amount for Section 21 (Fuel Sender) and Section 36 (Flap) — see Part A.

Rivet Tooling

• Corner Rivet Puller (Optional) — Section 10 (Internal Ribs); useful for reaching blind rivets in tight internal rib locations.
• 1/8" Offset Rivet Set — Section 14; allows setting rivets where the gun cannot reach straight-on inside the tank structure.

Fitting & Precision Tools — Section 13 (Fuel Cap / Tank Fitting)

• Section 13 involves fitting the fuel cap receptacle into the tank skin. This is a precision step requiring tools not needed anywhere else in the kit:
  • Bore Gauge [0.5–1.0" / 12.7–25.4mm] — Section 13; measures the finished hole diameter to confirm the fitting seats correctly.
  • Outside Micrometer [0–1.0" range, accurate to .0005" / 0.013mm] — Section 13; measures the fitting OD to calculate required reamer size.
  • Reamer [sized for .5620" ±.0005" / 14.275mm ±0.013mm hole] — Section 13; reams the fuel cap receptacle hole to final size. Purchase only after measuring your specific fitting per KAI instructions.
  • Bushing Press — Section 13; presses the fuel cap receptacle bushing into the reamed hole. A bench vise with flat plates can substitute if a dedicated press is not available.

Locating Pins

• #30 Locating Pins — Sections 18 and 19 (tank skin closeout); used to align the leading edge skin to the tank assembly before final riveting. Often improvised from cut-down #30 drill bits or purpose-made from hardware store rod.

Fuel Fittings & Vent — Section 20

• Section 20 (Fuel Fittings and Vent) installs AN fittings and vent lines into the completed tank. These tools are unique to this section and not called out elsewhere in the kit:
  • Pipe Thread Sealant [Loctite 565 or equivalent] — Section 20; used on NPT pipe thread fittings only. Do NOT use on AN flared fittings — those use Fuel Tank Sealant (B2).
  • Sockets and Wrenches [11/16" and 3/4"] — Section 20; for torquing fuel fittings. These sizes are not called out in any other section.
  • Aluminum AN Hose End Wrench [4AN] — Section 20; required for tightening 4AN flared fittings. Aluminum wrench prevents galling the soft aluminum fitting hex. A standard steel wrench risks damaging the fitting.

Vans AF RV-15 Forum Tool Recommendation Roundup from Nov 2025 to Jun 2026

Rivet Guns (Pneumatic, Solid Rivets)

• 3X Rivet Gun (Sioux recommended): Generally preferred for the RV-15; handles both 3/32" and 1/8" solid rivets. Run at 40–45 PSI.
• 2X Rivet Gun (Sioux recommended): Better control for 3/32" rivets only. Ideal setup is to own both a 2X and 3X.
• Inline Mini-Regulator (Harbor Freight):One per gun — set once per gun and leave it to avoid resetting every tool change.

Blind / Pull Rivet Tools

• Milwaukee M12 Cordless Rivet Tool: Highly recommended for all LP-4 and MSP blind rivets. Battery-powered, fast cycle time, consistent head quality.
• Milwaukee M12 6" Long-Nose Extension (P/N 48-95-0100, ~$50): Essential for the RV-15 — provides clearance in tight spots, especially Section 27 cove rib Cherrymax rivets and aileron trailing edge areas.
• PRP-26A Right-Angle Pull Riveter: Alternate Right-angle access for Section 27 cove rib rivets; some jaw grip issues with Cherrymax (clean/lube jaws).
• Pneumatic Pull Riveter (Chief/Harbor Freight): Faster than cordless for high-volume LP-4 work if you have compressed air at the bench.
• LP-4 Head Adapter (DIY): 14-gauge steel/aluminum with a flat, tight-fitting hole — produces cleaner, flatter LP-4 rivet heads than the standard chamfered nosepiece.

Squeezer / Yoke

• Numatix squeezer (pressure-regulated, small/light): HIGHLY recommended for nut plate rivets and general use. Bleed, bleed, bleed again before first use.
  • Numatix pressure settings: 80 PSI for -4 rivets; 38–40 PSI for -3 rivets.
  • After adjusting the supply line pressure, always verify the pressure has fully recovered to the correct setting before squeezing any rivets. Test with a couple of pedal presses before setting live rivets.
• Pneumatic Squeezer with 4" Throat Yoke: Standard for most solid rivets. Have both a standard and deeper yoke if possible.
• Wing Skin Riveting Rails (DIY): Holds wing skins at comfortable working height — highly recommended given the large wing area.

Accessories

• Rivet tape: hold rivets in place with tape while flipping a sheet — prevents all rivets falling out when the sheet is inverted.

Dimpling / Countersinking

• C-Frame Dimple Die Set: Standard for most skin dimpling.
• Countersink Cage: Required for aileron counterbalance tube holes — test depth on scrap first.
• Trailing Edge Bending Block (DIY, 2x4 with routed groove): Community favorite for bending aileron trailing edges to the correct angle.

Deburring & Edge Breaking

• Pneumatic Deburring Tool (Avlite or similar): Worth it for the large number of holes in the RV-15.
• Scotchbrite Wheel in Die Grinder: Speeds up edge-breaking on the large number of skins — noted as a big time sink if done by hand.
• Fluting Pliers: Required for ribs — use liberally wherever the rib flange shows puckering on a flat surface.
• Dedicated bench grinder with two 6 in wheels. Consider one wheel Light Deburring for thin edges, the other Cut & Polish for a more agressive deburr on thicker edges.

Plans / KAI Display

• Dedicated Monitor on Arm (24"+ recommended): RV-15 KAI is digital-only — a monitor at eye level near the bench works well.
• iPad/Tablet: Lets you zoom drawings and carry plans around the structure.

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