Apr 24, 2023     Rudder leading edge cut - (1.0 hour)       Category: Rudder

Cut the leading edge skin on the rudder with a cutoff wheel on a die grinder. For now I left it 1/4” bigger in case I didn't lay out the cutout correct. I'll wait to do the final trim during the install.

  Apr 16, 2023     Rudder R/H Rear Lower Skin - (1.0 hour)       Category: Rudder

On the rudder rivet the patch to the R/H side rear skin and bottom rib with A4 rivets. My rudder was one of the first ones produced and the leading edge was not cut. Laid out the cutout on the skin,

  Apr 06, 2023     Primed access panel - (1.6 hours)       Category: Rudder

Turned on the garage heater and got the temp to 70 degrees. Scuffed the access panel cover and ring along with the rudder close out skin. Cleaned the three pieces with SPI Waterborne Wax and Grease Remover. Then wiped with wax and silicone free tack cloths (TCP Global). Primed pieces with SPI Epoxy Primer,

  Mar 05, 2023     Rudder Access Panel - (2.3 hours)       Category: Rudder

Decided to make another access panel but this time have five fasteners instead of four. The ring is made from 6061-T6 .032 and the cover is 6061-T6 .025. The holes for the #6 screws are drilled to a #28. Dimpled all the holes. Added a piece of 1/8” heat shrink, Stein Air (SA702B), around the tail light wires where the wires will exit the rudder. This is also where the access panel will be.

  Feb 27, 2023     Rudder Access Panel - (1.2 hours)       Category: Rudder

Drilled mounting holes and sanded the edges for the rudder access panel. I'll be using dimpled nut plates (K1100-06) for #6 screws.

  Feb 26, 2023     Rudder Access Panel - (2.6 hours)       Category: Rudder

Laid out the access panel in adding to the rudder. I have a tail light so this will be used to get at the wiring and inspection purposes. Cut those pieces out with a bandsaw and jigsaw.

  Mar 18, 2021     Purchased Anchor Nuts and Stainless Screws Category: Rudder

Purchased pack of 5 K1100-06 Anchor Nuts and 10 each MS24693C26 (AN507C632R6) Flush Stainless Screws from Aircraft Spruce.

  Aug 10, 2020     Purchased 3.5" round access panel       Category: Rudder

Purchased a 3.5" round access kit (P/N RD35-F25) from Experimental Accessories. $32 for the kit and $10 for shipping. I'll use this one as a template to make more as needed. This access panel will be getting installed on the right rudder rear lower skin to give me access to the tail light wiring and for inspection purposes.

  Jul 09, 2020     Riveted the rudder horn and left rear lower skin - (2.2 hours)       Category: Rudder

Installed the rudder horn with #5 solid AD rivets.
Installed the left rudder rear lower skin with A4 rivets.

  Jun 21, 2020     Riveting - (1.2 hours)       Category: Rudder

Finished riveting the trailing edge skin and the leading edge skin with A4 rivets.

  May 10, 2020     Riveted skins - (3.3 hours)       Category: Rudder

Started to rivet the trailing edge and leading edge skins with A4 rivets.

  Apr 30, 2020     Primed and cleco nose skin - (1 hour)       Category: Rudder

Primed the mating surface with zinc phosphate primer on the nose skin, rear lower skin, and lower spar fairing. Cleco the nose skin, rear lower skin, and lower spar fairing to one side of the rudder.

  Apr 27, 2020     Cleco trailing edge skin - (1 hour)       Category: Rudder

Fabricated a 24mm spacer block and positioned it between the 2” square aluminum bar and the workbench under the aft bottom corner of the trailing edge. Cleco the trailing edge skin to the spar and ribs.

  Apr 12, 2020     Installed ribs - (2.8 hours)       Category: Rudder

Cleco and installed the 5 trailing edge ribs and 1 nose rib with #4 solid (AD) rivets. Had to modify one of my bucking bars for the rudder bottom rib because of the tight angle.

  Mar 29, 2020     Riveted the doublers to the spar - (3.2 hours)       Category: Rudder

Made 3 aluminum shims, 6061-T6 .032, to go under the ribs where they attach to the spar. There was a gap because of the SD75R1-8 doublers.
Riveted the SD75R1-8 doublers to the SD75R2-3 spar with #4 solid rivets.
Riveted the 75R2-5 rudder hinge angles to the spar with #5 solid rivets.

  Mar 28, 2020     Primed rudder parts - (2.9 hours)       Category: Rudder

Used acetone to clean the rudder parts to prime.
Set up a paint area in the garage and primed the mating surfaces on the spar, ribs, and brackets with zinc phosphate primer.

  Mar 26, 2020     Deburring and cleaning parts - (1.8 hours)       Category: Rudder

Finished deburring and cleaning the edges on rest of the ribs, rear skin, nose skin, lower spar fairing, rudder horn. Cleco the spar and ribs to see how they fit together and tried to figure out where to put the tail light.

  Mar 25, 2020     Prepping rudder parts - (3 hours)       Category: Rudder

Unpacked rudder parts and took wrapping off of them. Removed the P/N stickers with laquer thinner. Removed burrs from the holes and edges on the rudder spar, hinge angles, and spar doublers. Brushed on cortec primer on the rudder tip angle to see how I like it.

  Dec 12, 2019     Purchased 750SD Rudder from Zenith       Category: Rudder

Drove to the Zenith Aircraft factory and purchased the Zenith 750 Super Duty Rudder kit.