Finished Elevators and Worked on Aft Three Bulkhead Assemblies

Yay! Rivets came in the mail and I was able to finally complete the elevators.

IMG_1877

Cleaned up the edges and deburred the longerons and J stiffeners.

IMG_1875

Matched drilled the aft bulkheads to the VS aft spar.

IMG_1876

Countersunk the tie down support.

IMG_1882

Dimpled the bulkheads. I think I found a problem with the plans. They called for dimpling the #30 holes in the web of the bulkhead. Note the two dimples along the edge of the tiedown bracket. they are keeping it from sitting flush against the bulkhead. I’ll likely need to undimple these holes somehow.

IMG_1883

Match drilled the next bulkhead to the HS attach bars and dimpled the flanges.

IMG_1885-1

Likewise with the next bulkhead…

IMG_1887.jpg

Ready for deburring, scuffing, and priming.

IMG_1888

 

 

Today’s Time (hours): 6.0
Empennage Time (hours): 137.0
Total Time (hours): 137.0

 

More Work on Elevators

Jared Solomon and Wes Greer stopped by today and helped move the elevators along. I really appreciate having experienced builders helping me out.  Things went really fast and their advice is incredibly valuable. Had lot’s of fun building together, too. Thanks guys!

Today we final drilled the tip ribs to one another and to the counterweight skins. We cut the foam trailing edge and trim tab ribs. We trimmed and deburred the trim tab skins. We trimmed the right elevator aft spar. We bent the closeout tabs on the left elevator skin. We fit and drilled the trim tab hinge. We clecoed everything together and fit/trimmed the elevator trailing edges.

IMG_1759

Jared and Wes went home and I continued building. Not even ten minutes unsupervised and I screwed up! I misunderstood the interface between the trailing edge extrusion and the elevator wing tip. I removed way too much material from the trailing edge. I didn’t realize that the wing tip would be trimmed and butt up against the trailing edge. Had I read forward to the “Empennage Fairings” section, I would have understood how this went together. Oh well… Ordered a new trailing edge from Van’s.

IMG_1765

 

Today’s Time (hours): 5.0
Empennage Time (hours): 85.0
Total Time (hours): 85.0

 

Elevator Parts Prep

Cut and deburred the edges of the elevator ribs and clecoed them together. Also cut and deburred the shear clips.

IMG_1755

Straightened and fluted the tip ribs. Deburred the edges of the ribs and the counterweight skins. Clecoed everything together. Ready for drilling.

IMG_1756

Copied the plans page with the templates for the foam trailing edge ribs and the trim tab ribs. Checked to ensure that the copy was 1:1 withe respect to the original.

IMG_1757

 

Today’s Time (hours): 3.0
Empennage Time (hours): 80.0
Total Time (hours): 80.0

 

Horizontal Stabilizer Front Spar

Got the font spar to the point where it’s ready to be scuffed and primed. This was way more work than it looked like in the plans. It all started with the spar caps. They had to be trimmed and deburred. Then they’re match drilled to the spar web. Then disassembled, deburred, reassembled. Then they are match drilled to the spar flanges, disassembled and deburred. There were approximately a million and one holes drilled and deburred in these things.

IMG_1697

IMG_1698

Then on to the spar doubler. The usual drill (no pun intended)… Deburr edges, fit, cleco, final drill, disassemble, deburr holes.

IMG_1699

Countersunk twelve of the holes on the doubler.

IMG_1700

And here are all the front spar parts ready for scuff and prime.

IMG_1701

 

Today’s Time (hours): 5.0
Empennage Time (hours): 53.5
Total Time (hours): 53.5

 

Horizontal Stabilizer Rear Spar

Started work on the horizontal stabilizer today. The first part involves preparing the rear spar.

Screen Shot 2019-05-27 at 9.59.23 AM

Deburred the rear spar and the rear spar doubler with the Scotch Brite wheel, files, a deburring tool and god old fashioned sandpaper. Got all the edges and lightening holes nice and smooth. Clecoed the rear spar doubler to the rear spar. Final drilled all the holes.

IMG_1687

Clecoed the 8  outboard hinge brackets to the spar and final drilled.

IMG_1688

Machine countersunk the two holes in the center of the spar.

IMG_1689

Fit, clecoed, drilled, disassembled, deburred, reassembled, and riveted the inboard hinge bracket assembly with the flange bearing in the middle.

IMG_1691

Deburred and scuffed everything. Ready for primer. I’m only going to prime the inside of the spar. the outside will be painted when I paint the airplane. I neglected to account for this when I built the VS and rudder. I’m assuming the primer can be stripped from the outside of those spars in preparation for painting.

IMG_1690

 

Today’s Time (hours): 2.5
Empennage Time (hours): 48.5
Total Time (hours): 48.5

 

Back to the Vertical Stabilizer

Got all my VS replacement parts from Vans and now that I’ve completed the rudder I can go back and finish the VS. Tonight I cut, fit, clecoed, drilled, disassembled, deburred and dimpled all the parts. Next I’ll scuff and prime them and then rivet everything together. I hope to have the VS all buttoned up next weekend.

img_1669

Today’s Time (hours): 2.0
Empennage Time (hours): 43.0
Total Time (hours): 43.0

 

Riveted everything together

I finished back riveting the stiffeners to the skins. I had one oops where a rivet got cockeyed just before I drove it. It left a ding in the skin but didn’t penetrate. I debated replacing the skin but opted to move on.

I used 3M F9460PC double stick VHB tape to secure the trailing edge extrusion to the skin and clecoed it together. I put some long rivets through every tenth hole or so, put the tape on both sides of the wedge, and used the rivets to properly register the taped wedge to the right skin. Then I clecoed it in place and removed the rivets.

I riveted the stiffeners and shear clips together. I removed the backing from the other side of the tape while I pried the skins slightly apart so the strip didn’t tear. I removed clecos as I worked my way to the top of the trailing edge. I pressed the left skin into the tape and clecoed every hole.

I mounted the counterbalance. I had to file a bit off of the forward corners to clear the shop heads of the rivets holding the counterbalance rib in place. I riveted the skin to the spar, and riveted everything else except the trailing edge. That will be tomorrow’s adventure.

I neglected to shoot progress photos along the way but here’s the result of today’s work…

img_1656

This is the tape I used…

img_1658

Today’s Time (hours): 6.0
Empennage Time (hours): 36.0
Total Time (hours): 36.0