Feb 28, 2024     Section 12 - Empennage Fairings 10 - (4.4 hours)       Category: Sec 12 Emp F

Finished section 12. I noticed I used epoxy with micro balloons instead of flox. This made a very smooth transition from fairing to fuselage but will have to be refinished by the paint shop team, for sure.

I have installed all control surfaces and connected the elevator trim. Elevator trim movement is reversed and will have to be corrected on VPX configuration. I found out that the control stick is showing some bad connection signs. elevator trim works but depending on the stick position it quits operating momentarily. I will have to redo the harness connection. The passenger side seems to be working perfectly. I also tested trim actuation through the touch screen and works fine. Reversed but fine.

https://youtu.be/fS05hPkBFoc

  Feb 27, 2024     Section 12 - Empennage Fairings 9 - (7 hours)       Category: Sec 12 Emp F

Almost finished with the tail feathering. It is a small part installation but it requires a lot of work. Dimpling, countersinking, dimpled nut plates, normal nut plates, squeeze riveting, bucking rivets, epoxy, wax coating, fiber cutting... A lot for one single part.

One final session and it will be done.

https://youtu.be/1WXw62Mvnnw

  Feb 26, 2024     Section 12 - Empennage Fairings 8 - (1.7 hours)       Category: Sec 12 Emp F

I'm installing the elevator/rudder fairing. Not much progress today due to limited time at the hangar but a milestone date. Today is the 3rd anniversary of this project. Exactly 3 years ago I opened the first kit box and started this journey.

https://youtu.be/MUFhKF4JwGQ

  Feb 25, 2024     Section 12 - Empennage Fairings 7 - (2.8 hours)       Category: Sec 12 Emp F

In this work session, I am working on the vertical/horizontal stabilizers fairing, and gap covers. I have used a different technique to blind drill holes and it worked well. I drew two lines that will converge to the center of the hole and then, after the fairing is put in place I redrew the lines and found the hole spot. Works like a charm. I learned this technique from a smart builder from California called Andrew Kilroy. @akilroy Thanks, buddy! Really helpful!

https://youtu.be/KY0tr4_ssA4

  Aug 26, 2021     Section 12 - Empennage Fairings 6 - (7.1 hours)       Category: Sec 12 Emp F

Work session executed in 3 different days.

The work done on this round was around finishing up the rudder and vertical stabilizer and installing rudder navigation lights. I found out that most of the time, the fairings will require some art work. add mass with epoxy flow or balloons, sand and redo... until you get them to the correct shape.

For the Empennage kit, this is it. I concluded all tasks possible to conclude prior to final assembly.

On the final assembly process, I will rework final touch on fiberglass seams with aluminum. I need to talk to a painter first though to make sure I am not doing work that will have to be redone later on the painting process.

For the light connector, I decided to mount the male end on the light. the female end gives more protection for hot wires.

https://youtu.be/ycRUSS3DjO0

  Aug 20, 2021     Section 12 - Empennage Fairings 5 - (4.1 hours)       Category: Sec 12 Emp F

On this session I disassembled the elevators and stored it for future. During the final assembly I will make final cosmetic touches. Need to learn more about painter job before preparing surfaces.

Following this step I worked on the bottom rudder fairing. This is a removable fairing that will house the tail navigation light. It has to be attached by screw and nut plates. To do that I had to use the fairing itself as a guide to mar hole locations on the attach strip. Using a nut plate with a screw in it, I had a guide to drill the #40 holes that secures the nut plates.

All nut plates were dimpled and dimpling the attach strip on the tip of the rudder trailing edge required a method other then pneumatic squeezer. I used rivet gun with dimple die 3 male plus the tool that is screwed on a workbench that I almost never use. Came in really handy.

To rivet these rivets I used indirect back riveting sandwiching back rivet plate against bucking bar and hammering the back riveting plate with the rivet gun and mushroom set. Worked really well too.

Installed the #6 flush screws, 0.5mm above fairing surface. I added some epoxy with micro balloons on some openings on the tip of the fairing to try and sand it of to make it flush on both sides of the rudder.

Next step is to install light, wiring and, maybe, countersink fairing screw holes a bit more.

https://youtu.be/vj7rRDt6rlc

  Aug 14, 2021     Section 12 - Empennage Fairings 4 - (3.9 hours)       Category: Sec 12 Emp F

On this session I finished the right elevator and horizontal stabilizer tips. Closed up the fairing with a fiber cloth patch and riveted in placed.
I planned to smooth up the surfaces using epoxy with micro balloons but I ruined a batch of 4 strokes of epoxy and a fair deal of micro balloons... After mixing the compound I remembered I had to prepare the surface. by the time I tried to apply it, the mixture was very hard to work with and not adhering well to the other materials..

I decided not to make any finishing on the fairings until I talk to people who know how the painting job is taking care of these details, or not..

https://youtu.be/Hr6FH61wo8A

  Aug 12, 2021     Section 12 - Empennage Fairings 3 - (4.5 hours)       Category: Sec 12 Emp F

During this work session I have disassembled the left elevator to redo part of the rolled aluminum at the leading edge of the elevator. I had to do that because there was a minimal rubbing against the aft spar.

After adjusting the curvature of the leading edge and re riveting it, I reinstalled the control surface and redid the clearance test successfully.

Moved on to the next step which was fabricating the fiber glass cover for the tip fairing of the left half of the horizontal stabilizer. With the part ready and drying I moved on to the right elevator fairing tip.

For the right elevator fairing tip, what I did was to add a extra layer of epoxy and flox to the interior of the fairing where the aluminum surfaces overlaps, giving me more room to sand it deeper to accommodate aluminum skin thickness while still able to countersink it. Worked perfectly and it all went together very fast.

https://youtu.be/jk1CBIf8GrY

  Aug 11, 2021     Section 12 - Empennage Fairings 2 - WITH HELPER - (3.3 hours)       Category: Sec 12 Emp F

On this work session I had George over and he helped me disassemble the whole tail. We then cleaned up the stops for the elevators rounding corners as per Van's recommendations and primed the exposed aluminum parts.

Following that we stored the fuselage to make room for the next phase, the wing kit. Fuselage will be stored for a long time now. it is concluded just waiting for mating the forward fuselage in maybe 2 years from now... hopefully less..

Moving on, we reassembled the horizontal stabilizer and elevators. We torqued the jam nuts to the correct torque and finished adjusting right elevator for full clearance from aft horizontal stabilizer spar.

Couldn't finish the left elevator though. Next work session I will revisit it. I believe it will be necessary to remove the pop rivets and rework the bending on leading edge of left elevator.

https://youtu.be/DwxA6mEgDAk

  Aug 07, 2021     Section 12 - Empennage Fairings 1 - (5.4 hours)       Category: Sec 12 Emp F

Started the process of attaching the empennage fairings. I decided to begin with one side only and learn from it before making double mistakes. I am working on the assembled structure but planning to separate sub structures to complete this process easier. Plans tells to start with rudder but, given the assembly being in place, I've decided to start on the left elevator fairing.
Making the first cut was very easy with a dremmel tool on high rotation using metal cutting disc. cuts like butter. A lot of care needed to avoid cutting more then needed.

After cutting, I started match drilling #40 holes. I Also did a little of sanding on the small indent on the fairing where aluminum parts will rest. it would be necessary to sand more then I actually did but material was getting thin, way too much to accommodate the machine countersinking process that has to be done on fiber.

Afraid the rivets would come through the fiberglass, I plan to add more epoxy - flox on the right fairing, specially where there is an overlap of aluminum sheets where the counterbalance connects to the elevator.

After assembly, I have an edge of 1/32 approximately, that I will have to deal with later. maybe some filling before priming on the outside of the part.

The front of the fairing is shorter than the actual aluminum on the front portion of the counterbalance. I will fill it up with some epoxy - flox mix later and sand it to shape.

After the elevator fairing was done, I started the tip horizontal stabilizer fairing. this process involves closing the aft end of the piece. I tried to make a different process to create the fiberglass part putting a layer of peel ply bellow the epoxy, on top of the aluminum part, instead of using wax.(as manual recommends) it didn't work. the part is ruined and it glued to the aluminum mold, even with peel ply between glue and metal. looks like peel ply doesn't stick to epoxy but epoxy do goes through the peel play.

Will have to re-do this part. (see "58.33")

https://youtu.be/PZPie-u_3T4