Archive for August, 2005

Rudder riveting

Sunday, August 7th, 2005

Since I need to wait for replacement ribs to continue with the elevators, and I got my pneumatic squeezer back from being rebuilt at Clear Air Tools, I switched back to the rudder. Here the skeleton is coming together:

I used solid rivets to attach the rudder brace to the bottom rib, but I wasn't able to get any of my squeezer yokes inside the brace in order to squash the horn-to-brace rivets, so I used the optional LP4-3 blind rivets there. I could probably have used solid rivets if I'd ground down the top corner of my longeron yoke, but who cares.

The rudder counterweight is installed in its home with nuts and screws. I wonder why this weight is pre-drilled but the elevator ones aren't…?

Here the skins have been riveted to the spar.

Next step is the trailing edge, for which I obtained a big piece of 1/8" aluminum angle from the aviation department at Ace Hardware. Clamped to the rudder trailing edge, match-drilled, and held with a cleco in every hole, it will serve to keep the trailing edge perfectly straight while I glue it together and then rivet it.

But that will have to wait for another night since Mary wants to take me for walkies in the park.

Right elevator work

Saturday, August 6th, 2005

This morning the right elevator skeleton started coming together:

Then the skin got clecoed on and match-drilled:

As did the elevator horn:

Oops! Here's the first mistake on the elevators. I followed the instructions and drilled through the counterweight into the E-703 and E-704 ribs, but the drill got off-center and the resulting holes in the rib flanges are too close to the edge for the nut that's supposed to fit there. I thought about elongating the holes, but decided against it. That means I get to buy a new counterweight and two new ribs on Monday.

Then I repeated the above steps for the left elevator, and it all turned out okay. So at least I don't have to redo the counterweight ribs on both elevators.

Bent the elevators

Thursday, August 4th, 2005

Tonight I made a homebrew bending brake out of some 2×6 lumber and some door hinges, and used it to bend the elevator skins to their final shape.

When I had each one bent as far as it'd go with the bending brake, the open end of the skin was still bobbing in the air about an inch above the spar. Following the advice of those who've gone before me, I used hand seamers (cushioned with duct tape to avoid scratching up the skin) to gently squish along the trailing edge until the skin was resting on the spar.

I was a little worried about this whole process, but it turned out great and was a snap. Next stop looks like deburring and straightening a lot of ribs, so I think I'll quit while I'm ahead.

Oshkosh

Monday, August 1st, 2005

Back from working four days at Oshkosh. I didn't get a chance to take many pictures since I was in the booth most of the time, but here are some from a ride I got to take on Friday. Unfortunately that's not me in the Extra 300, but I did get to ride along in the photo ship (a restored Beech 18) and take some pictures of my own. The Extra is being flown by aerobatic pilot Michael Mancuso, and the guy in front is some lucky stiff. As you can see, it was completely awesome.

 
 
 

I also managed to sneak away from working long enough to head over to Vans' booth and order the RV-7 quickbuild wings and fuselage.