May 11, 2024     Horizontal Stabilizer Rigging - (7 hours)       Category: Empennage

Lots of paranoia trying to set up and rig the tail, but it is all done. One mistake when the nicopress tool moved a tiny bit and one ferrule is not exactly where it should be, once the cables were taught, it solved the issue but I will work on fixing it. The excess wire will be cut off once I get some flat cutters that will flush cut through that much wire.

Today was the first day the assembly has been on the ground, it was then rolled out of the hangar so I could sweep. It felt like a small success.

  Apr 21, 2024     LH Horizontal/Rudder Install Pt. 1 - (2.5 hours)       Category: Empennage

Mounted front brackets on to tail boom for horizontal stabilizer to mount to. Also did the top rivets for elevator control horn into the elevator. Front and rear of horizontal stabilizer are both 7/8" from the tail boom tube, spare .875 tubing confirmed it prior to riveting horn in elevator.

Because I don't have all the fancy jigs to hold everything in the perfect spots, I invented a new one, which actually worked pretty well.

  Mar 24, 2024     Horizontal Drama - (3 hours)       Category: Empennage

Research and measuring. Finally think I figured out how these things are supposed to be attached.
Drilled and riveted on the stainless steel brackets where the leading edge areas attach to the tail boom tube. Then, on the offhand as I was about to take the picture of the pair, I found the horizontal tube of the LH to be about 1/2" shorter than the RH, which would explain the odd angle when I was attaching the elevator and hinges.

So.. I will buy yet more tubing to fix yet another mistake I have made. I have enough tubing to fix the inboard tubing but not enough for the leading edge. I may also have to make new cross-braces, I have extra of that too, thankfully.

  Mar 20, 2024     Tail Build Pt. 3 - (1.5 hours)       Category: Empennage

Finished bracket mock up and alignment of lower vertical assembly. All holes drilled and cleco'd in place.

Going to have to buy more clecos, I have 5 left that are not in use.

  Mar 17, 2024     Tail Build Part 2 - (1.5 hours)       Category: Empennage

Upper portion of vertical and respective brackets now all drilled and aligned to center point of tube. Rolled tube upside down for bottom portion of vertical and marked for center point of tube.

  Mar 15, 2024     Tail Build Pt. 1 - (1 hour)       Category: Empennage

Mocking up the vertical fin. Got it on to the boom tube with a little effort and aligned it on to the end of the tube as flush as I was able to. Drilled the 2 holes for the control arm, and to assist in vertical assembly alignment.
Had to borrow a couple tools as I did not have any wrenches in the hangar; only cutting, drilling, and bending. Things to bring next time!

Next steps will be to work on mounting leading edge angle brackets that secure vertical to the tail boom tube on both upper and lower sides.

  Mar 13, 2024     Tail Prep - (.5 hour)       Category: Empennage

Set the tail tube on saw horses and kayak rack foam blocks, then secured with ratchet straps. Should be ready for figuring out how to mock up vertical stabilizer and then horizontals after that.

  Feb 24, 2024     Tail Hinge Drilling - (3.5 hours)       Category: Empennage

216 holes drilled and manually deburred for vertical to rudder and horizontals to elevators.

  Oct 30, 2023     Vertical Stabilizer Pt. 5 - (1 hour) Category: Empennage

Made brackets to hold vertical stabilizer assembly to tail boom tube once I get to that step.

  Oct 25, 2023     Vertical Stabilizer Pt. 4 - (1 hour)       Category: Empennage

Installed upper ribs and brackets, finished installing final gusset. Next step is making the brackets to hold upper and lower sections to tail boom tube.

  Oct 24, 2023     Vertical Stabilizer Pt. 3 - (1 hour)       Category: Empennage

Cut and fit tube for vertical stabilizer. Riveted at trailing edge on both sides. Mounted leading edge gusset to RH side. Once left side is done, will work on fabricating brackets to mount assembly to tailboom tube.

  Sep 03, 2023     Vertical Stabilizer Pt. 2 - (2 hours)       Category: Empennage

More vertical stabilizer finished, did everything that could be done until the ordered tubing arrives in a week or two. Lower tubes cut to length, drilled, and riveted in to place.

  Aug 20, 2023     Vertical Stabilizer Pt. 1 - (5 hours)       Category: Empennage

Started vertical stabilizer. Bit more nerve wracking when the steel section isn't as replaceable as the aluminum tubing is. Either way, minus one mistake on an angle, which shouldn't be a problem, I'd say it's about halfway. Did one wrong cut on the original diagonal tube so have to head to metal supply store to order more to finish the lower tubes.
Tape used for mock up purposes, but is doing a fabulous job.

  Aug 18, 2023     Horizontal Stabilizers Pt. 5 - (2 hours)       Category: Empennage

LH horizontal stabilizer now done. Forgot how I did the first one so I made one small mistake that I can deal with, it is not in a stressed area.

  Aug 15, 2023     .032 Sheet Metal Category: Empennage

Ran out of sheet metal to finish brackets for the support ribs of horizontal and vertical stabilizers. Picked up some extra today.

  Aug 08, 2023     Horizontal Stabilizers Pt. 4 - (3 hours)       Category: Empennage

Finished RH horizontal stabilizer. LH stabilizer frame finished. Going to buy more .032" aluminum sheet tomorrow to finish making rib support brackets for LH vertical stabilizers.

  Aug 07, 2023     Horizontal Stabilizers Pt. 3.5 - (2 hours) Category: Empennage

5 support rib brackets made, bent, drilled, and 3 mounted on RH stabilizer frame. Not enough material to make the remaining 4 needed.

Made all the support tubes for both sides and then saw the small side picture showing to not crimp the tubes, which I did. So, I will be remaking them tomorrow and starting that whole process over..

  Aug 05, 2023     Horizontal Stabilizers Pt. 3 - (2.5 hours)       Category: Empennage

Right hand horizontal stabilizer frame cut to length and riveted on both sides. Inner frame next.

  Aug 04, 2023     Horizontal Stabilizers Pt 2 - (2 hours)       Category: Empennage

Made a couple very lucky mistakes so figured it was time to stop for the night. Inner and trailing edge of RH horizontal stabilizer are now riveted together on both top and bottom at 90 degrees with its respective gussets.
Cut leading edge tube to rough size.

  Aug 03, 2023     Horizontal Stabilizers Pt. 1 - (2 hours) Category: Empennage

Prep work to start assembling horizontal stabilizers. Cut inner tubes to proper angle. Added internal sleeve for future hinge placement, and riveted in place per instructions. Drilled vertical hole not quite perfectly vertical for cable hold down for RH side; appears I can adjust for this down the road with washers.

  Jul 17, 2023     Horizontals / Elevators - (2 hours)       Category: Empennage

Started cutting the materials to length for horizontal stabilizers and elevators. 7/8" tubes are now cut to length, as are all the hinges. Did get ahead of myself and cut the hinges for the flaperons but figured since I was cutting hinges that I might as well. An aluminum cutting blade for the "new to me" miter saw cuts pretty nice.