Title: 09-04 - Elevator Skin Close-out Tab Forming
2/08/2021 – 1.6 hours Construction of the elevators introduces a few new tasks including actually bending metal. In this case, I had to clamp the skins to the workbench in a very specific way, and then bend the close out tabs from the flat skin inward 90 degrees. A mistake on this step will ruin the skin, so I spent a lot of time re-reading the procedure in the plans, setting up the piece correctly, and confirming that I was bending the tabs the right way. I used a 1' x 2' x 10” piece of wood with rounded edges as my bending tool I laid the piece of wood on the tab, and smoothly worked it down the side of the work bench to make the bend. The plans recommend hitting the bend with the rivet gun at low pressure to set the bend, but I found a rubber mallet did the same job with a lot of control and no marring of the skin. I finished the bend after unclamping the skin from the workbench with a hand seamer to get a good 90 degree bend. I was really nervous about this step, but I was very happy with the results. After finishing the bends, I moved back into more familiar territory by trimming the end of one of the rear elevator spars as specified in the plans. [Clamps, Wood Block, Rubber Mallet, Hand Seamers, Dremel with 1 1/2" Metal Cutting Wheel, 6” Grinder Wheel, 6” 3M Cut and Polish Wheel, Deburring Tools, Maroon Scotch Brite Pad] 2/11/2021 – 0.5 hours This step ended by marking the forward and aft section of the piano hinge for the trim tab, and then drilling pilot holes in each section of the hinge. I used a digital caliper to measure and check the hole locations, and a ruler to re-check the locations. We'll see how well I did when the rest of the piano hinge holes are match-drilled with the other trim tab pieces. [Digital Calipers, Ruler, #40 drill, Pin Punch]


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