Empennage

Elevator ( 3 hrs )

Step 5 at Sect 9-09:   Dimple #40 holes (3/32") on Counterbalance Skins.    Requires using Modified male Dimple die to avoid overlapping TE bend (reduced outer diameter at surface or face).   Completed Top & Bottom LH Elevator Skins.  Next doing same for RH Elevator skins.   Getting close to time to Prime then begin final assembly (yeah !)

Empennage

Elevator  (2 hrs )

Con'td  Sect 9-09 Step 4:   More deburring all holes and edges of Tip Rib Assembly (6 parts) and 4th of 4 Skins.    Scuff where planning to prime, before dimples.     Step 6 ahead of Step 5:  Used tool to "break" the TE of Counterbalance Skins  - to insure won't "curl up" when riveted.  Did now ahead of Van's step to dimple adjacent holes.    Takes time to edge deburr !

Empennage

Elevators  ( 5 hrs )

Continued Sect 9-09 at Step 3.  Finished Final Drill #40 and #30 for all holes on RH Elevator.  Then marked parts and dis-assembled.

Began Step 4:  Deburr all holes and edges.  Major Task for so few words in instructions!
...all four Skins, all Sparts, Shear Clips,  etc.   So many holes, and both sides of course.  Requires considerable time  - good music helps, along with comedy podcasts.

example skin edged, holes deburred, and scuffed.  Next step Dimples.

Note: I follow this order:  Deburr holes,  Deburr edges, Scuff ONLY surfaces that are mating with "work" done (ie intact Alclad will not be scuffed in open surfaces),  then Dimple (easier to scuff prior to dimple).   Next Acetone clean, and finally spray Primer on specific locations.

Still have 1 0f 4 skins to deburr holes and edges, and Tip Rib Assemblies.

Empennage

Elevators ( 2 hrs )

Sect 9-09, Setp 2 Attached (cleco'd) LH and RH Elevator Horns.   #30 (ie 1/8" holes) drilled at twelve times each horn - but those rivets are critical !

 Step 3: Final Drilled all mating part holes not already done for Elevator assembly.  Then dis-assembled - but critical to mark parts for later re-assembly.  (used permanent marker with tape over to protect as scuff, acetone clean and prime parts.  these are in areas entirely still covered 100% Alclad, so remain corrosion protected after remove tape at re-assembly)  Only got RH Elevator completely "done", so planning next session to do same for LH side.

Empennage

Elevator  ( 2.5 hrs )     April 6 , 2016

Cont'd Sect 9-08, Steps 2 & 3:  Cleco'd RH and LH Tip Assly's to Bottom Skins and Shear Clips.   Final Drilled #30 holes 6 places each at interface to sub-assembly structure.

Counterbalance skin goes UNDER the Top Skin.

Step 4: RH Top Skin cleco'd w/ Trailing Edge added.    Unique TE w/ thicker at end (Van's adjusted pitch sensitivity & control harmony on the RV14's with this small detail).    Trimmed off excess length of TE, grinding to fit perfectly while also deburring edges.     Per instructions, matched end to E 912 composite tip with slight taper top and  bottom.  Didn't take much, because tip has some thickness of several fiberglass layers at it's own TE.   Repeated for LH Elevator (much shorter TE due to Trim Tab).  

Impressive how top and bottom close out tabs fit perfectly with Shear Clip.  I'd bent these 90 deg earlier, with one at 1/32 and one at 1/64 from bend line, to allow for overlap.

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.