Apr 03, 2021     Section 7 - Rudder 9 - (5.5 hours)       Category: Sec 7 Rudder

Section 7 concluded. Rudder trailing edge turned out perfect. very straight and tight. Bending the leading edge was not easy and took a little time to get it in the correct shape. For the trailing edge I followed the process from Section 5 manual and squeezed the rivets in 3 steps always checking the alignment before squeezing the next tighter. Used special dies from Cleaveland tools.

When attaching the leading edge surfaces I noticed that the metal sheet break for overlap was a bit to much. next time I will make it lighter.

I'm uploading a picture of the training kit trailing edge (22.1) to show the difference in results. the practice kit the edge was not straight at all... huge improvement.

https://youtu.be/-6VGag7FemM

  Apr 02, 2021     Section 7 - Rudder 8 - (3 hours)       Category: Sec 7 Rudder

Almost done with section 7. I think one more work session and it will be concluded. In this session I have riveted the bottom part of the rudder with all the components. It is really key to follow the exact process and steps suggested on the plans. the rudder horn brace squeezes in place very tightly but perfectly. if you rivet any rivet out of order, it would no fit in.
So far the AD4-6 rivets on the bottom of the horn brace were the hardest ones to set. very very tricky positioning and no space to work with any bucking bar nor squeezer.

Trailing edge is looking super straight. Important to monitor the alignment as all the parts are getting riveted to make sure it will remain straight.

Couple of mistakes on this phase. I realized I haven't dimpled the front flanges of the tip and counterweight ribs.. Quick fixes for next session.

https://youtu.be/UKnzmYnBc18

  Mar 27, 2021     Section 7 - Rudder 7 - (3.5 hours)       Category: Sec 7 Rudder

Preparation of rudder skins for rudder assembly. Installed all stiffeners, trailing edge wedge and pop rivet skins together.

Very confusing the fact that one hole of the stiffeners is not supposed to be riveted.. But I went through the manual thoroughly and asked for help and looks like it really is what is supposed to happen.

https://youtu.be/YJ_LnlezQAM

  Mar 21, 2021     Section 7 - Rudder 6 - (4 hours)       Category: Sec 7 Rudder

Material preparation and priming of all rudder and vertical stabilizer components.

400ml of primer used.

https://youtu.be/UZ6fONnuaFE

  Mar 20, 2021     Section 7 - Rudder 5 - (3 hours)       Category: Sec 7 Rudder

Dimpled all rudder parts. Countersunk the trailing edge wedge using a very nice method. placing the wedge over another piece of wedge makes it stay flat for an easy countersinking process.

Also masked parts for priming. In have all pars for vertical stabilizer ready to go. this will be the next session.

https://youtu.be/q3-KRFhp_S8

  Mar 18, 2021     Section 7 - Rudder 4 - (3 hours)       Category: Sec 7 Rudder

On this work session I built a painting table using Van's kit crate and chicken wire. installed some legs and wheels so I can pull it to the driveway for painting and then back into the garage.

On the rudder, I did the match drilling of trailing edge. I came up with a nice solution to make the hole perpendicular to the cord by inclining the whole structure using blocks of 2x4 wood and clamping the structure in place. Doing so, I was able to drill perpendicular to the work table and cord of wedge at the same time. The wedge came drilled at final size and proper angle. but skinks needed to be matched. I used #40 rimmer for all holes instead off drill bit.

Following this process, disassembled everything and deburred. Next step was putting a break on the skin edge. this was hard at first. I am still not sure if I over did it or not. hope not. one of the skins I broke the edge towards the outside. wrong. had to redo it but looks like it won't be an issue. The aluminum accommodated well the re bending towards the opposite side.

https://youtu.be/oPNGLya7lVM

  Mar 15, 2021     Section 7 - Rudder 3 - (4 hours)       Category: Sec 7 Rudder

Prepared the counter weight rib, match drilled, countersunk lead bar and dimpled the rib for holding the lead counter balance. Finished off the skins by trimming the flanges and bending the edge of the flange. Assembled the whole structure to start skin match drilling. The tip of the rudder is not quite easy fit. A little bending and adjusting were needed to place the last two clecos on the tip of the rudder where the counterweight resides. Other than that everything very smooth. Stiffeners went in like a glove. Nest step, match drilling skin and dimpling. Still haven't placed one single rivet.

https://youtu.be/V1LiEhTe9vo

  Mar 13, 2021     Section 7 - Rudder 2 - (6 hours)       Category: Sec 7 Rudder

During this work session I've finished cutting all parts and deburring them. Rudder skins are ready for dimpling and edges are deburred.

https://youtu.be/7BxYhMarkjQ

  Mar 13, 2021     Section 7 - Rudder 1 - (1 hour)       Category: Sec 7 Rudder

Started working on the rudder assembly. Basic inventory, separating parts to start deburring and cutting parts.

https://youtu.be/QStYDCzM35I