When complete all captive nuts were fixed using the supplied 1/8'' countersunk pop rivets.
Note: One set of the holes are close to the flange to allow the use of even a small micro-stop if one was available. Trying to use only the cutter resulted in a nick into the metal which had to be polished out. This set of holes were counter-sunk using a 7 mm drill. This was done with the battery drill running at the minimum possible speed with extreme, extreme care. The clutch was set to just drive the drill.
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| Frame ready for skinning |
Port Frame
Assembled the frame and fixed with the supplied dome head rivets.
Port side skin refitted and fully clecoed except to the attachment to the main spar to allow fitment of the D nose.
Starboard Frame.
Assembled the frame and fixed with the supplied dome head rivets.
The skin was refitted and clecoed to the frame.
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| Elevator Trim |
The unused portions of the ribs projecting from the skin were marked and the clecos from the first two ribs were removed once side at a time, the rib's are cut with aviation snips. The skin re-clecoed and the operation repeated on the other side.
Modification: Refer disclaimer
Trim Tab Mounting
The folded 90 degree angles for the frame were prepared and mounted. The top angle needed more that 90 degrees and after correcting the angle it was was curved by the process used - time to stop and think about it.
The conclusion was to begin again with new folded angles that were manufactured at the correct angle and had larger flanges making assembly less critical.
Schematic's of the assembly scheme is shown below and is unapproved - refer disclaimer above.
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| Elevator Schematic |
Elevator Trim Modifications
Two [2] angles were folded from 2024-T3 aluminum to match the opening profile at the rear of the frame. One was folded wider than the opening to be trimmed later. Both have a 20 mm flange to match the original.
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| Rib preparation |
The lower angle was fitted first with its overall depth reduced by 3 mm from the measured dimensions of the openings. Fitted the angle's 20 mm flange into the rib and match drill two mounting holes at adjacent ends using the skin and checked the alignment.
Once satisfied all the remaining holes were drilled and the angle secured with clecos.Two aluminium angle tabs were fabricated to suit their location and attached at each rib with 2 [two] pop rivets, The lower angle was secured to each tab [rib] with a single 1/8'' counter sunk rivet after dimpling. This allows the top angle to be fitted on top.
The upper angle was positioned above the lower flange and drilled using the same method outlined above.
Using a straight edge the bottom was alignment was checked, then using clamps, fingers and eye the lower angle [rib skin location] was adjusted into its final location. Particular attention was taken to ensure the line of the skin follows the correct line of the rib profile. It was a balance between a straight line and the rib profile visuals.
Starting at the outer rib, drilled the first hole at the base and fix with a 5/32'' cleco, repeated the process at the opposite end then the center. This process created a single element that locks the top and bottom skins into their final location.
With a final check using a straight edge and eye, checked the overall appearance and when satisfied the last task was to drill the balance of the holes in the lower row then fix with 3/32'' rivets.
Note: The location of all mounting holes were marked using the drilling jig supplied by the factory using a felt tip pen.
The 3/4" wide piano hinge supplied with the kit was separated into its two components then one was drilled to match the rivets on the elevator at a 30 mm pitch to accept 3/32'' rivets.
Positioned the hinge and match drill the skin and spar - fixed hinge with 3/32'' pop rivets.
This blog must be read in conjunction with this later blog - Hitting a Wall
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