Archive for June, 2005

Started Rudder

Sunday, June 26th, 2005

Today I got started on the rudder. Its construction is a little different from the vertical and horizontal stabilizers – rather than having a one-piece skin which folds around a set of ribs, the rudder consists of two thin, floppy skins that are given their strength by aluminum angle stiffeners every few inches.

To cut the stiffeners to the proper lengths, I used this cheap cutoff saw I got at Harbor Freight last year. But first I had to squint at the plans for a while to figure out just what they wanted me to do here. They don't exactly go out of their way to make it clear.

Here are the stiffeners for the right-side rudder skin. At this point they are only rough-cut to the approximate shape, but not smoothed and deburred. I'll probably pick up a cheap benchtop belt sander to finish these guys off.

Here's a shot of the stiffeners for the left-side rudder skin. I guess I could have omitted this photo since it looks a lot like the previous one, but here you go anyway.

Finished Vertical Stabilizer

Saturday, June 25th, 2005

Mary was awesome again and came out to pound in the skin-to-forward-spar and skin-to-middle-rib rivets:

Then the rear spar gets clecoed on…

…aaaaaaand, done. The vertical and horizontal stabilizers are finished, hooray!

Got the VS ready to rivet

Thursday, June 23rd, 2005

I didn't get to fly as much tonight after work as I'd planned, so I got to work on the RV just a little bit. I swapped air connectors so I could run the rivet gun – as an aside, boy do I not like using the air tools without my handy swivel connector and my lightweight couplers – and smashed in the rivets that attach the ribs to the lower part of the forward vertical stab spar. Then, everything gets clecoed together:

I'll have to make sure to be extra nice to Mary so she'll be willing to come out to the sweltering garage to pound in these rivets this weekend…

VS spar riveting

Wednesday, June 22nd, 2005

I managed to find enough normal-sized air couplers laying around the garage to get the squeezer hooked up, so I was able to get the rear vertical stabilizer spar riveted together:

(Note that I keep an ample supply of lubricant available to make the work process go smoother)

The next step has you rivet the VS ribs to the front spar. I managed to get the upper and center ribs attached, but the geometry of the lower rib/spar interface has me stumped. I guess I'll either figure out a way to get the squeezer on those rivets, or I'll just smash them with the rivet gun. In that case, I have to wait for the new air fittings to arrive on Friday so I can get my regular air lines hooked up again and run the rivet gun.

Primed VS parts (again!)

Tuesday, June 21st, 2005

Tonight I primed the replacement vertical stabilizer spar parts…

…and I also decided to lightly scuff and prime along the rivet lines inside the skin:

So I was all set to start riveting this baby together, when my Avery lightweight air coupler somehow came apart.

Of course one of the five little steel balls rolled off into a dark corner somewhere, so even if I could get the stupid thing back together, it probably wouldn't work right. Oh well, a new one is only six bucks, and I was going to pick up a few other things anyway, so back to the Avery website we go.