Building the Elevators

The last subassemblies that need to be built in the empennage are the right and left elevators. The two elevators are different in their construction due to the trim tab being part of the left elevator. Like the rudder, the elevators are built with skins that have stiffeners fastened to them. The elevators differ from … Continue reading Building the Elevators →

Finishing the Rudder

The final tasks on the rudder assembly are the riveting of the trailing edge (earlier bonded into place using tank sealant), riveting of the hard-to-reach narrow sections of the top and bottom ribs, the setting of the rivets inside the lower brace, and the curving of the leading edge. The rivets in the narrow aft … Continue reading Finishing the Rudder →

Elevator Stiffeners

While I'm waiting for my rudder trailing edge to cure, it seems like a good time to move on to the next sub-assembly: the elevators. Like the rudder, the elevators have relatively thin skins that are stiffened using light aluminum angle. These stiffeners need to be cut, trimmed, and smoothed before they can be installed. … Continue reading Elevator Stiffeners →

Rudder Final Assembly

Almost done with the rudder! I've assembled and riveted the skins and the counterweight assembly on the top of the rudder: The lower rib, horn, brace, and fairing attach strips are riveted together on the bottom of the rudder: The rivets holes inside the brace (now held by clecos) are impossible to reach with my … Continue reading Rudder Final Assembly →

Rudder Assembly and Drilling

Today's building session was spent assembling the rudder, final drilling the rivet holes, and fabricating the lower fairing attach strips (R-918). The first task is to assemble the skeleton which includes the main spar, a lower rib, and the upper counterweight section. The skins are then clecoed to the skeleton. I had one fit issue … Continue reading Rudder Assembly and Drilling →

Riveting Rudder Stiffeners to the Skins

Having trimmed, smoothed, deburred, primed, and dimpled the rudder stiffeners and the left and right rudder skins, it's now time to rivet the stiffeners to the skins. I'm using the back-riveting technique for this task, which involves driving the shop heads while the flush factory heads are held against the hard smooth surface of a … Continue reading Riveting Rudder Stiffeners to the Skins →

Rudder – Stiffeners

With the Horizontal and vertical stabilizers completed and set aside, it's time to start building the rudder assembly. The first task is to trim and prepare the stiffeners so they can be riveted to the left and right skins. The rudder skins are significantly thinner and lighter than the skin on the vertical stabilizer. To … Continue reading Rudder – Stiffeners →

Vertical Stabilizer Completed

All of the parts for the vertical stabilizer have been ready for final assembly for some time now. It's time to get this assembly finished as well. The vertical stabilizer is much simpler and has taken much less time than the horizontal stabilizer. Once the skeleton is riveted together, it is ready to be fastened … Continue reading Vertical Stabilizer Completed →

Horizontal Stabilizer Completed

This evening I had a visit from my EAA technical advisor. We had arranged to get together for the second time right before completing the horizontal stabilizer so he could inspect the interior before it was closed up. We talked about the project so far. I asked about a number of mistakes I had made … Continue reading Horizontal Stabilizer Completed →

Horizontal Stabilizer – Ready for Inspection

It's time to permanently assemble the horizontal stabilizer. The front and rear spar assemblies are complete and everything is primed and ready to go. The assembly starts by clecoing and riveting the HS-707 rib to the top side of the skin. This rib is in the center of the front section of the stabilizer. It … Continue reading Horizontal Stabilizer – Ready for Inspection →