Apr 01, 2005     Fitting rudder to vertical fin and fin aft spar - (40 hours)       Category: Rudder

After assembling the rudder, we proceeded to fit the vertical fin aft spar on which we mounted the two rudder hinges. That took some trimming of both the top of the vertical fin and aft edges of the fin. Part of the rudder projects over the vertical fin which showed us a problem with that gap so there would be enough clearance so the rudder would not scrape the top of the vertical fin. The vertical fin aft spar waa also a problem since we could see when we inserted the spar between the vertical fin sides that the fin and rudder were not parallel. So we trimmed and fitted and finally got it to work.

  Oct 30, 2004     Installing the rudder lead counterweight - important! - (4 hours)       Category: Rudder

The rudder counterweight made of lead, we wrapped in tape to keep the lead from touching the aluminum rudder skin and therefore prevent dissimilar metal corrosion.

  Oct 30, 2004     Riveting rudder skin to forward spar. in rudder - (5 hours)       Category: Rudder

Once we lined up the forward rudder spar and rudder skin, we drilled and countersunk the holes and drove rivets for attachment.

  Feb 13, 2004     Riveting the rudder parts in correct alignment - (80 hours)       Category: Rudder

We then started driving rivets to put together the first parts of the rudder we worked rather slowly since we wanted to make sure all the pieces stayed aligned. Also, we were learning how to use a #2 rivet gun and bucking bar. And, of course, choosing the correct rivets and drill bits for the holes. We were feeling our way in this enormous project which would take us many more years that we anticipated.

  Jan 11, 2004     Building parts of the rudder - (15 hours)       Category: Rudder

On each of the rudder ribs and the spar we marked a rivet row centerline. We used a Sharpie in a special holding tool which allowed us to slide it along at a constant distance from the edge of the rib lip. The Sharpie would then leave a black line to delineate the centerline for rivets. Building the rudder was the first time we had to learn how to drive solid rivets. We quickly found out it wasn't easy! Yes, we had to drill out a few.

  Jan 03, 2004     Rudder spar alignment before first rivets are driven - a big moment to start our Sportsman - (50 hours)       Category: Rudder

Brutus bought a GlaStar tail kit way back in 1997. But he never built the tail assembly. After getting the boxes home Brutus realized this was a project which he would prefer to share with at least one other builder. He first approached Dee while Dee was running his Two Wheel Travel bicycle shop in Richmond, VA, but Dee told him he didn't have time to join him in the project, especially since Dee was an active member of the Wingnuts Flying Club Ltd at KFCI. So after Dee closed his business and Brutus and Nancy built a new house with a 3-car garage, he approaded Dee again, and after some serious thinking, got "Yes" for an answer. However,l within about 2 weeks, it became obvous to them, they would like a talented 3rd partner, so Stratford Ward entered the partnership. For at least 3 months, on our two 8' tables, we set up a jig to align the rudder spar. This was our first of many attempts to be very, very precise in building this our dream kit plane. And, this was the first time we ran into a question we would wrestle with time and time again, namely, "How good is good enough?" This is a question that the very detailed two-volume Sportsman manuals did not address except in rare instances. Still, we were pleased with our rudder when we finished it.

But we were not pleased when we checked the vertical stabilizer which is part of the fiberglass fuselage and found out that was not only twisted but leaned to the left so that a plumb bob hung from the top center, was way off at the horizontal stabilizer level. There are other photos that show how we improved that alignment, a lot...but could not get it really correct because it was so far off out of the Glasair factory mold. Poor quality control. That misalignment was one of the reasons we chose to add the optional electric aileron trim kit. Note one of the photos shows Brutus and Stratford laying out the line of rivets. (We never bought the special tool which makes spacing a row of rivets a snap.) But we are proud of the rudder!