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Bills RV-7 Build Site
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Date:  6-26-2013
Number of Hours:  2.50
Manual Reference:  6-13
Brief Description:  Roll elevator leading edge

Tonight I tackled the dreaded task of rolling the leading edge of the elevator. Think of it as if you were rolling aluminum foil around a pencil. Except the aluminum foil is very thick and stiff, so you have to use a steel pipe, vice grips and all your might to get the metal to bend at all. I first tried to do all sections of the leading edge at once, as I had read in the forum that a number of people have done this. I used clamps and spacers to hold the pipe down against the table top, but just couldn't get enough twist on the pipe to get an adequate bend. So I resorted to doing it a section at a time, 3 sections per side. Taping the pipe to the skin is the most time consuming part, as it takes several layers of duct tape to get enough strength to hold while the pipe is being twisted. 2 hours later I had all sections bent enough that I was able to cleco everything together and then riveted the lower section. I still have some minor gapping in the mid section so will try to work that with my hands before I try to rivet it.
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Top section rolled and clecoed

Top section rolled and clecoed

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Lower section riveted

Lower section riveted

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End view of bends

End view of bends

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