Empennage

Elevators (2.5 hrs )

Nancy and I flew our flying club's C172 from Lacon (C75), Illinois to Effingham, Illinois (1H2) on Friday - just for fun.  Visited Mid-America Motorworks (free - w/ lots of Corvettes), and had a great lunch at the Firefly Grill.

So....I skipped building on Friday, but back at it Saturday.  Now with 3 days curing of the Foam Ribs (Tank Sealant/ProSeal ), did the final Root Ribs & Tip Ribs rivets.  Then the T.E. flush rivets using the "RV14 Safety Pin Squeezing Tool".   Tool is critical for reverse wedge on TE.

 

Empennage

Elevator  (2 hrs )

continued Sect 9-24 with Step 6-9 (after Priming cover and C Channel supports) for Pitch Trim Servo Assembly.   No "slop" in clevis pin to pushrod...a good fit.

Step 4 included Labels onto Trim Harness at each end, and trimming corners of Molex connector so fits through the bulkhead bushing.   Also applied silicone to seal end of Molex connector.

Empennage

Elevator  ( 1 hr )

Sect 9-24, Step 1 & 2:  Bent hinge pin to nest into channel at Inboard end of LH Elevator.  Relatively easy to bend this "wire" (vs piano wire I've used before on R/C planes which is heat treated and tends to break at sharp bends).  Drilled 1/16 inch hole adjacent...ready to safety wire once Trim Tab is actually installed.

Jumped ahead slightly to Step 5:  Pitch Trim Servo Assly.   For the #27 size holes, used #6 screw dimple dies (tested first with sample material same thickness...screw head fits well).  Then Countersink six  #40 holes that attach the support C-channels.  I first tested depth on sample material (0.032")...key since thinner material than typically countersunk.  Happy with results.

Empennage

Elevator ( 2 hrs )

Hooray !  Sect 9-23 Steps 1-10.  Successfully bonded all 8 Foam Ribs into LH and RH Elevators.  Added TE to each, using the double sided tape process.  Just cleco'd for now while "tank sealant" (Pro Seal) cures for couple days.  

Used lots of weight -everything but the kitchen sink on boards to compress top skin onto foam ribs and bottom skin.  Even used my C-Frame, and a few bricks too.

Empennage

Elevator  ( 2 hrs )

Sect 9-22 Steps 2-4 for LH Elevator - Outboard close out done.  Finished remaining Rear Spar rivets w/ RV10 bucking bar (those left open to enable lifting skin for outboard riveting access).  Last time I need this special bucking bar...but sure works great.  

I'm glad I recognized Skins go over Counterbalance Skins. (Van's has bold text statement in later page of the Elevator build...but key was knowing this during original assembly with clecos.  Good to read ahead ! )     Fit is "flush" - better than I'd anticipated with this overlap.

Empennage

Elevator  ( 2 hrs )

Sect 9-22 Steps 6-8:  Rh Elevator Outboard close out done.  Several different lengths of rivets kept me checking instructions frequently.    Two rivets are reached via lifting open the Skin and inserting the bucking bar inside.  

I found easiest to do with Elevator set as shown in picture below... instead of from bottom and top simultaneously.  

Finally got to squeeze in all the rivets along Front Spar on top and bottom.   Tomorrow I'll do the LH Close out.  Soon...bonding in Ribs and TE.

Empennage

Elevator  (3.5 hrs )

Big day today....joined Front Spar with Tips to the Skins, etc. It's been a long journey for the Elevators (seems as long as the Rudder + Vert Stab + Horiz Stab combined...)  

Bottom side LH Elevator...Front Spar installed.  "Stored" while work on RH side...

Sect 9-20, Steps 7-9: Riveted LH and RH Front Spar Assly's into Elevator Skins at Ribs with 18 blind rivets each side.  Very satisfying to have perfect alignment of all holes.

Sect 9-21, Steps 6-8: jumped one set ahead to complete Inboard Close-out of RH Elevator, since already on the table.  Tricky 2 rivets to E 921 Gusset - requires lifting corner of skin to reach shop ends.  My wife's smaller hands were really helpful.  Thanks Nancy !  

RH Inboard Close-out...done

 Steps 1-5:  Back up one set of instructions to do LH Elevator Inboard Close-out.  Again, several challenging rivets requiring lots of patience.   But each time figured out best way to position bucking bar (even one time able to use Main Squeeze to reach inside).  

Started Sect 9-22, Step 1 and Step 5 riveting Shear Clips to LH and RH Outboard Tips.   Tiring work today due to many different set ups and tools, and lots of reading and re-reading to be sure understood instructions and process expected.