Empennage

Elevator (0.5 hrs)

Cont'd Sect 9-07:  Completed Steps 4-6 for Trim Tab Hinges - Drilled #40 holes, and trimmed ends flush.   Re-assembled to check alignment....seems very good.

Aft hinge 1/2 match drilled to Trim Tab Spar

re-assembled:  fits great.   Will trim rod later....

Sect 9-08 at Step 1:  Drilled small gussets in Left and Right Elevator assemblies.

Empennage

Elevator (4 hrs)

Continued Sect 9-04 w/ Step 4 & 5.  Drilled 2 holes in end of Trim Tab Hinge while designating one Aft and other Fwd half.  Sect 9-05 Step 1&2:  Drilled 2 holes in Left Front Spar at 3/8" and 5/8" using Uni-Bit (tested/practised 1st w/ drill press on sample alum since 1st time doing this procedure).   Cleco'd Left and Right Front Spars to Bottom Elevator Skins.

Right side shown

Sect 9-06 Steps 1-4:  Assembled Ribs to Front Spar & Bottom Skins, along with Rear Spar and Root Rib.  Also added Gussets and Shear Clips.    Left side has more w/ doubler, etc for Trim actuator mounting.

Left side with Trim Tab mounting, etc.

Sect 9-07 Steps 1-3:  Positioned precisely Fwd 1/2 piano Trim Tab Hinge.  Match Drilled #40 with extra care to insure aligned...1st with clamps, replacing with clecos as hole drilled.   Trimmed excess length of hinge.

Trial re-attach Aft Hinge ...perfect alignment since pin slips in easily. 

Step 4:  Cleco & Clamped Aft 1/2 Hinge to Trim Tab Spar.   Ready to match drill tomorrow.

Empennage

Elevator (1.5 hrs)

Sect 9-03, Step 3.  After removing vinyl at Close Out Tabs on Left Top & Left Bottom Skins, marked bend lines.  This sets up  Sect-04 Step 1 & 2 for each with set-back (one at 1/32, other at 1/64). Slightly staggers overlap, when assembled.  Used wood block to bend initially by hand.  Used rivet gun on low setting with wood block to easily finish the bend line - not too crisp, but consistent.  Finished to 90 deg with hand seamer.

Bend at edge of table. 

 


Step 3:  Trimmed 1 of 2 Rear Spars for Left elevator.

Empennage

Elevator (4.5 hrs)

Sect 9-2  Step 4:  Used hand seamer to adjust flanges to 90 deg on both E-904 Inboard Ribs and both E-903 Outboard Ribs.    At Step 5, fluted each to insure all holes along flanges in a straight line - considerably more needed than typical on prior parts.   Re-checked the 90 degs, and tweaked a few locations.  Per instructions, insured holes are straight by "cleco'ing" the Counterbalance Skings to the Ribs.  Perfect fit and alignment.

Steps 6 & 7: Assembled Tip Rib Assembly.  Cleco'd, and Final Drilled  (#30 Reamer) holes in mating Ribs, and FD the holes (#40 reamer) in flanges to Counterbalance Skins (2X).

Pic shows where Elevator Tip Fairings will fit  -  but not until much later at Sect 12-05.  Curious about fit, etc....

Sect 9-03, Step 1:  cut out templates from page 29 (actually used photocopies after insuring true 1:1 size).   Worked well to apply spray adhesive to each surface.  Bandsaw cut out Foam Ribs.  Used a gentle touch on 6" Disc sander to finish edges to the template's lines.  All Foam Ribs finish sanded, and ready to use.

  

Sect 9-3: Step 2:  For Trim Tab Skings, removed hatched areas per plans for Close-Out Tabs at each end.

Empennage

Elevator (1.5 hrs)
Finished Page 9-2 Step 1 by deburring all edges...a LOT of edges for all 12 Ribs.  Time consuming, but good to get these done today.

Step 2 was simply cleco'ing together top and bottom Ribs.  The 12th one is top only, since later it will be joined to part of Trim Tap mount for lower portion.

Empennage

Elevator (1.5 hrs)

Started by reviewing (again) entire section for Elevators (29 pages).   HIghlighted special instructions , unique tools, etc.  

Sect 9-2 at Step 1:  Started with separation of E1008A and B ribs.  Used bandsaw first, then grind edges to lines.  Will deburr entire pieces soon.    Also jumped to Step 3 to separate and deburr the 3 Shear Clips while I was using bandsaw.

Edges not yet deburred.

Empennage

Horiz Stab (2 hrs)

Cont'd Step 4 on Sect 8-12:  Finished 3 more sides along Rear Spar.  Pleased with straightness and no waviness.    

Squeezing last few 426  3-4  flush rivets along Rear Spar.

Removed H.S. from four cradles, and rotated into "flat" position onto carpet over work tables.

Finally riveted center two Nose Ribs, including 5 (x2) rivets to Front Spar  using 470 rivets 4-7 and 4-8.

Needed the Offset cup rivet set tool in the rivet gun to reach these.   Required increasing pressure several clicks -- seems offset absorbs considerable energy.

Done with Sect 8 !   On to Elevators in Sect 9....