Empennage

Empennage Fairings ( 0.5 hrs )

Re-mounted the Horiz Stab, Vertical Stab, Elevators, and Rudder (also Empennage Gap Covers) today to examine fitup...and to take some pics.   I'm considering some blending between Elevator Tips and HS Tips, as well as between Rudder and Vert Stab.   They're really good, but now that they're installed, I can see some variations between front to back.   Won't help plane fly any better, just cosmetic.   Maybe later during Finish Kit, etc.     I do plan to "smooth" between Horiz Stab Tip and HS Skin, but the initial fit is near perfect.    

Hooray !  Essentially done with Empennage Kit. (expecting QB Wings and QB Fuselage delivery in couple weeks)

From Jan 1, 2016...Empennage Kit "completed" Sept 2016.

A long way to go...but closer !

Empennage

Empennage Fairing  ( 2 hrs )

Monday, Sept 20

Sect 12-09 Completed Steps 1 & 2 to install Empennage Gap Covers - LH and RH.  This required using a 12" long #40 drill to reach from opposite side of VS to drill from inside outward.   Each Gap Cover needed slight grinding at few locations along upper edge to fit properly to bottom skins on Horiz Stab.  

Clecos installed as holes drilled from other side with 12" long drill bit.  Marked aft edge and trimmed to flush, too.

Van's supplies the Empennage Fairing (upper fiberglass piece) in Finish Kit...so I have to wait for Sect 12-10 to -13 to really complete this area.     So...I'm going to re-install Elevator and Rudder to check the tip fairing alignment with HS and VS.  Then disassembly and store.

Expecting QB Wings & QB Fuselage delivery by Tony Partain trucking in early October...a couple weeks !

Empennage

Empennage Fairing  ( 1.5 hrs )

Sect 12-8:   Deburred all edges and holes on LH and RH Empennage Gap Covers.  Bent in 3 places each per instructions.  Trial fit onto Aft Fuselage, and ready to go.   Taken back off so I can re-mount the HS, and VS.

Empennage

Empennage Fairing  ( 1.5 hrs )

Sand...sand...sand.    But "done" with Elevators and Vert Stab now.   And previously Rudder was "finished".    Only have Tips on Horiz Stab to do, but will wait until mounted with Elevators to check surface alignments, etc.

 I'm ready to move on.

Empennage

Empennage Fairings ( 1 hr )

2nd application of epoxy resin with 410 Microlight onto Vert Stab Tip (left and right sides), and top and bottom of LH & RH Elevator Tips.   Needs to cure 12 hrs...so 'hafta' wait.

Empennage

Empennage Fairing  ( 1 hr )

Sanded both sides of attached Vert Stab Tip, and both LH & RH Elevator top sides.   They need a second pass of epoxy filler to be done.

Empennage

Empennage Fairings ( 2 hrs )

Monday, Sept 12

Attached  Vert Stab Tip after dimpling aluminum and Countersinking fiberglass.  Mixed 410 Microlight into epoxy, then applied to same VS Tip,  plus LH and RH Elevator Tips on top side now. First sanded surfaces with 400 grit followed by good cleaning with isopropyl alcohol.   (note:  this time slightly too much microlight mixed in  ...seemed a little harder to apply smoothly via squeegee.  I'll try a little less for second pass to fill in remaining rough spots after sanding)

after rivets, before applying filler

filler applied.  cure time more than 12 hours

one of 2 Elevator tips...top sides now

Empennage

Empennage Fairings (2 hrs)

Sand, sand sand...   Rudder - Tip & Bottom (at strobe transition only),  LH & RH Elev on bottom sides,  and Vertical Stab Tip at new fiberglass end plate.

Vert Stab Tip with chamfer 
added to inset endplate

 

Rudder bottom 

Right side of Rudder Top

Left side of Rudder Top

Empennage

Empennage Fairings ( 1 hr )

Added chamfer to inset of Vert Stab Tip Fairing.   With left over epoxy resin, I smoothed in transitions from aluminum to fiberglass on bottom RH Elev, and Rudder Top Tip.  Sand with 400 grit first, clean with isopropyl alcohol.  I'm getting better at smoothing with squeegee.  Trying to reduce amount of sanding.   Next..sand off most...only leaving low spots filled.  

Rudder Tip  ( applied 1st pass both sides)

RH Elev  (1st pass, lots of sanding next)

Empennage

Empennage Fairings (2 hrs )

Cut fiberglass patch that cured overnight, and trimmed to fit into Vert Stab Tip Fairing.  I prefer to inset about 2mm vs flush, so I have better clearance to swinging Rudder, but from sides appears only 3mm clearance.  Kind of matches appearance of Vert Stab meeting Rudder, Or Horiz Stab meeting Elevators at hinge lines, too.  Plus I was able to force Tip into more accurate profile matching Rudder Fairing.    I inserted patch, then "tacked" into place using cyanoacrylate glue.   This allows me to immediately follow up with reinforcing with fiberglass strips and resin on inside.

After fiberglass strips on inside cure, I'll add "chamfer" of epoxy filler on outside

Since I had extra epoxy resin, I added 410 Microlight to peanut butter consistency so I could apply another layer to LH Elevator at transition from Tip to Alum.  This was after sanding first application...and this will likely be final.

Second application of epoxy filler...after sanding first layer.

Empennage

Empennage Fairings (2.5 hrs )

Sect 12-07 Steps 1-3 completed for Vert Stab Tip Fairing:  trimmed to fit.  Even though Van's instructions don't include,  I mounted the Rudder to insure proper 3mm clearance.   Glad I did, as slight adjustment (angle of front of Rudder) was appropriate for a consistent gap.   Once in position, I drilled #40 holes & reamed with #30 to allow me to remove and re-attach as I checked clearance.  Quickly made fiberglass patch.  I had plenty of resin, so also mixed in West Systems 410 Microlight to start smoothing in the transitions from alum to fiberglass.   Close up appearance will be improved, but going to keep to a minimum so I limit unnecessary weight.

checking with template.  Green layer is release ply.

Empennage

Empennage Fairings ( 1.5 hrs )

After fully curing, I sanded with 400 grit the perimeter chamfer on LH & RH Tip Fairings.  Installed in Horiz Stab via blind rivets.  Fits great - really solid.   I also sanded the leftover filler I applied to front of Elevator tips to blend in to Counterweight aluminum.  I like how easy this was to sand, yet seems very tough material with great adhesion.

Filler sanded smooth

Attached.

Empennage

Empennage Fairings ( 1.5 hrs )

Only took a few minutes to dimple Horiz Stab and C'sink Tip Fairings.  Then I mixed West Systems 105 resin with 206 Hardener, adding in 410 Microlight (microspheres) until reached a "peanut butter" consistency.  With this much microlight added, expect it will be easy to sand.   Applied around perimeter of inset fiberglass sheet to create a smooth chamfer.   Since I had extra, used to start smoothing in leading edge of LH & RH Counterweight transition to fiberglass on Elevators.   Since need to cure several hours, time to go swimming !

after removing tape...

Empennage

Empennage Fairings ( 1.5 hrs )

Friday, Sept 2

Steps 5 - 7, Sect 12-06 now done for both LH and RH Horiz Stab Tip Fairings.  Ready to dimple HS and C'sink fiberglass...then blind rivet - but need to wait for epoxy resin to cure.

Empennage

Empennage Fairings ( 2 hrs )

Cut out new fiberglass "sheet" to fit into LH Tip fairing.   Decided to reinforce with 3/8" square balsa from top to bottom to insure Tip fairing was properly "expanded", and would not bow in or out (which could cause an interference).   I recessed approx 1/16" so no possible interference with swinging counterweight on Elev.   Being "inside" insured correct profile too.  With Tip fairing installed via cleco's on Horiz Stab, I simply used cyanoacrylate (instant glue) to hold in position.  Removed and added fiberglass layer to inside to secure to Tip.   It's really solid now !    I used same batch of epoxy resin to make RH Tip plate ( 2 x 9 oz cloth layers).