Attached right elevator tip

Same drill as as the left tip… Final drilled #30, remove counterweights, dimple reinstall and torque counterweights, countersink tip, cleco, and pop rivet.

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Tada

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I used this bit on the Dremel to cut some fiberglass and phone out of the middle of the HS tip to correct the fitting issue I mentioned yesterday. Not a precision instrument. At least not in my hands. But it got the job done.

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I added a temporary foam block to hold the correct width.

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I used some masking tape to compress to the correct width. And adjusted to an interference fit with the HS skin.

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Cut some cloth to fit the inside of the tip.

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Added epoxy and set aside to cure. Once it’s hard, I’ll remove the temporary foam spacer and backfill the gap I cut with micro at the same time I fill the front side.

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Today’s Time (hours): 2.0
Empennage Time (hours): 203.0
Total Time (hours): 203.0

 

Attached left elevator tip

I final drilled #30 the elevator skin to the tip. Then I removed the tip and countersunk the holes.

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I dimpled the holes in the elevator.

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I had to remove the counterweight to dimple the forward two holes. Then reinstalled and re-torqued the nuts.

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Installed the tip with CS4 pop rivets. I’m thinking I might replace my pop rivet tool. I’m getting a burr on the top of all of the rivets and I’ve had several break off in the tool. I’m careful to keep the tool perpendicular to the work but this keeps happening. A while back, a mandrel got jammed in the tool. I disassembled it to remove the mandrel and reassembled it. But I think the jaws are not grabbing properly now.

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In other news, you can see that after trimming and sanding the left HS tip, it fits nicely. The right tip is another story. I think I neglected to final fit it after I sanded the foam or perhaps I seated the foam too deeply. In any event, it spread the tip about an eighth too far and now the tip wont fit between the top and bottom skins at the spar. I’ll noodle on how I might salvage the part for a while and If I can’t I’ll order a new one. My best thought at this point is to take a 1/8″ wedge out of the middle of the foam/fiberglass with a saw and then put  another layer of glass over it.

 

Today’s Time (hours): 1.0
Empennage Time (hours): 201.0
Total Time (hours): 201.0

 

Forward Spar Assembly Complete

Riveted the doubler and spar caps to the forward spar.

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I received the torque wrench I ordered from Amazon and torqued the nuts securing the inboard hinge bracket to the rear spar.

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Both forward and rear spar assemblies completed. On to the ribs…

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Today’s Time (hours): 2.0
Empennage Time (hours): 58.0
Total Time (hours): 58.0