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My Airplane Projects
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Date: 1-24-2009
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Number of Hours: 2.00
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Manual Reference: 09-10
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Brief Description: Finished stabilator.
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A real in and out, up and down day today. Was in and out of the shop all day supervising kids riding the tube run and serving up hot chocolate. Before all that started I was showing Carolyn how nicely the horizontal stabilator and servo tab hinges meshed - and they did - one at a time. When I tried them both at the same time however, it was impossible to make them fit! Further investigation showed that when I had riveted the control horns to the end ribs on the servo tabs (for the second time, see entries for 1/10 & 1/14) I had once again let the parts separate slightly during the riveting process. Turns out there is literally NO tolerance for this, because of the extremely tight spacing between the left and right tabs when they are mounted to the hinges on the stabilator. See picture below. Only recourse was to rework the parts. Drilled out the rivets holding the end ribs to the skin, and removed the assemblies. Drilled out the squeezed rivets holding the ribs to the control horns and separated the parts. Could clearly see the extra space between them. Held the two control horns together and found they just barely slide between the ends of the tabs when they are mounted on the hinges. No extra space at all. All four parts look pretty beat up, so decided to order new parts from Van's before next attempt.
Jack and I clecoed, match drilled, and riveted into place the aft skins per instructions. Then we temporarily installed the counterbalance arm, and final drilled the counterweights and installed them. Jack figured out a way to remove the drilled off rivet head that was rattling around inside the stabilator - thank you Jack!
The mail came with the CS4-4 replacement rivets from Van's. Installed 8 of these into the spar holes under the control brackets, then installed the brackets and torqued them down.
Carolyn cleaned the shop for me and I put away all the tools that were scattered around. Now have to figure out where to stow the completed stabilator and get down the fuselage skins to start on the next sec
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Extremely tight tolerances.
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Finished spar attachments.
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Counterweights - drilled by Jack.
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