Multiple updates - vert stab, elevators, rudder and fuel tanks

Sorry for the lack of updates.  We've actually been working but I just haven't taken the time to update the site recently.

 After the inspection we worked on wrapping up any of the things that the inspector noted.  First up was re-doing the rolled leading edge on the rudder.  It was a fairly simple job.  What it did point out was the increased level of confidence in our abilities.

After that we moved onto working on the ailerons.  We did most of the work but we simply aren't happy with the results.  The skins is a little too wavy and that can induce drag and lower our speed.  We've decided to redo them now that we have more experience with metal.  It will equate to about 7 hours of work but it'll be worth it.

We then closed up the vertical stabilizer.  It's now completely finished and ready for installation on the fuselage (once that it ready).  

After that we got to work finishing up the trim tab (it's a part on one of the elevators that is kind of like cruise control in a car) and then the right and left elevators.

Finally we continued working on the fuel tanks and have sealed one of the tanks.  We need to let the sealant cure before we pressure test it.

What's left?  We have to rivet the trailing edges on the rudder and both flaps and seal the last fuel tank.

February 16th

The rudder's inspection sticker.

Scott squeezing a few rivets.

Darren Squeezing a few rivets.

A finished piece!

February 19th

Darren squeezing some rivets on the trim tab.

February 21st

Scott working on our ultimately unsuccessful attempt to fix up the ailerons to our satisfaction.

February 26th

The elevator prior to attaching the trim tab.

Scott working on attaching the trim tab.

Darring sqeezing some rivets.

Scott showing off the installed trim tab.

A finished piece! 

March 5th

A shot of the tack prior to riveting.

After riveting.

Inside.

 From the side.

Finished elevator (non trim tab side).

Empennage completed

Today we finished up the remaining tasks on the empennage (at least those we can do prior to inspection).  We installed the trailing edge wedges by match drilling to the top elevator skin, through the wedge and into the bottom skin.  After that we deburred and dimpled the skins and machine countersunk the wedges.  We then prepped and primed the parts.  Finally we rolled the rudder leading edge.  We spent the remaining time cleaning and reorganizing the shop. 

We'll start on the wings on Tuesday. 

The left elevator layed out with the piece of "L" aluminum used to assist in drilling out the trailing edge.  

 Scott drilling out the trailing edge.

Darren deburring.

Left Elevator Final Assembly

Sorry for the late update.  This update will contain 2 Tuesday evening's worth of work.  We finished the assembly of the left elevator.  We attached the ribs, trim spar and attach gusset.  We also assembled the counterbalance arm and attached the bottom skin to the main spar.  Finally we riveted the trim spar and ribs to the bottom skin and assembled the trim tab motor housing.  There are a few minor tasks to wrap up on the empennage (rolling the rudder leading edge and drilling out the trailing edges) before we move onto the wings. 

Scott unpacking the trim tab motor. 

A look at the contents of the trim tab motor's box. 

 Marking the trim tab motor's cover, and mounting brackets.

The assembled trim tab motor housing. 

 Trim tab motor attached to the housing.

 The trim tab cover shown in place on the elevator.

A close up shot. 

The wide angle shot.

Left Elevator Assembly

Today we made quite a lot of progress on the left elevator assembly.  Our first task was to dimple the rest of the skin and then we prepped and primed it.  Next we back riveted the stiffners to the top skin.  We then assembled the the counterbalance ribs and skin.  After that we riveted the main spar, reinforcement plates and plate nuts and attached the rib.  The next step was to attach the main spar to the top skin and the stiffners to the bottom skin.  The final step was to attach the plate nuts to the trim tab motor reinforcement plate and attach that plate to the skin.

Left elevator prep work

Darren was away this weekend so I did a few things to get us ready for work on Tuesday night.  I dimpled and deburred a few of the parts.  With the exception of the skin, I prepped and primed all the parts.  On Tuesday we'll finish dimpling, prep and prime the skins.  If there's enough time, we'll start assembling the right elevator. 

Left Elevator Progress

Tonight was a mix of tasks.  We manufactured an attach gusset (it reinforces the joint between the rib and the trim tab spar).  We finished match drilling the last few holes, deburred and dimpled the ribs.  We machine countersunk the trim tab spar.  We also begain prepping the finished parts for priming.  We have a few more parts (the spars and the skins) to dimple and then it will be time to prime and assemble the elevator.

We noticed we have not created the gusset piece yet. 

The specifications.

Scott working on creating the gusset. 

Darren showing off is skills gained as part of the government workforce.... Looking busy... but what is he doing????

Finished Right Elevator Assembly

Today we spent time doing the final assembly of the right elevator (for those who are watching closely we moved our building day to Sunday this week).  We first attached the main spar to the top of the skin.  The elevator skins are pre-bent so this was actually quite difficult as we needed to hold the skins apart to rivet the spar and skins together.  We next back riveted the stiffners to the bottom skin before riveting the main spar to the bottom skin.  We did this with a combination of solid rivets and pop rivets.  We used our new pneumatic pop-rivet gun (a cheap investment but really cool) which made this step a breeze.  Finally we riveted the ribs to the skins.

Before we left for the day we brought the left elevator down and got ourselves oriented for the work on Tuesday. 

The new pneumatic pop/blind rivet gun.  A Princess Auto special. 

Scott setting up a jig to hold skin open while we rivet the skin to the skeleton.

The skin clamped into place.

 Scott operating the new pop riveter.... It is unecessary but a nice to have.

Time to pull out the Left elevator.

Start of right elevator assembly

Tonight we started the final assembly of the right elevator.  The first step was to attach the hinge reinforcement plates and the nut plates.  We next attached the bracket and riveted the top stiffners to the skin.   Finally we assembled the counter balance ribs and attached the skin.  this was a logical spot to stop while we take a few weeks off.  Our next update will be on May 24th.

Darren squeezing a rivet on one of the hinge reinforcment plates. 

Scott squeezing a rivet. 

Scott performing some riveting on the elevator skeleton.  We bought the longeron yoke for our squeezer so we should be able to avoid using the rivet gun for the similar peices on the left elevator.....  

 The skin after the top stiffeners have been attached.

Skeleton assembled, and some work finished up on the skin.... 

Right elevator primed

Tonight we added an extra few hours to wrap up the priming of all the parts for the right elevator.  Nothing too exciting but absolutely necessary.  We'll be able to start assembly of the right elevator on Tuesday.

Rudder Assembly and Right Elevator Prep

There's not a lot to say for the work today.  The plan was to assemble the rudder.  Before we started we primed the counterbalance skin where the main rudder skin overlaps it.  There was quite a lot of riveting to do but the rivet squeezer saved us a lot of time.  We assembled as much of the rudder as possible (had to leave the trailing edge and one of the bottom sides open for inspection).  The last thing we have to do is to roll the leading edge.  

Before we quit for the day we finished dimpling the right elevator skin. 

Scott performing some assembly work.

 The skeleton awating the attachment of the skins.

 Darren rereading the instructions to make sure he didn't miss anything.

 Scott working with the pneumatic rivet squeezer.

Darren standing next to an almost completed rudder.

Organization, Horizontal Stabilizer and Rudder

Tonight was a bit of a hodgepodge as we moved a few things to our storage site (Darren's).  We then finished up organizing some of the rivets and other key parts.  We also assembled one of the elevator hinges for the horizontal stabilizer (pretty much the last task on the horizontal stabilizer before the inspection.  Finally we resumed work on the rudder.  The part arrived last week and we match drilled, deburred, dimpled and primed the counter balance rib.  Before we called it a night we machine countersunk the counterweight.  We're ready to assemble the rudder on Saturday.

Finishing up unpacking and orginizing the rivets.

I have a feeling there is still lots of riveting left to do...... 

 Time to finish up some unfinished business on the horizontal stablizer.

 The hinge cleco's together and awaiting assembly.

  The hinge cleco's together and still awaiting assembly.

After riveting the hinge together, it was time to get to work on the rudder.