Brief Description: Completed empennage control surfaces
After finally receiving the correct backordered 03 ribs, I was able to finish all 3 control surfaces. The rudder came out fine but the elevators have a problem.
It appears the trailing edge on the right elevator is about 3/8” lower than the left. When I site down the trailing edge of both left and right elevators, there is no warp, just the entire right side trailing edge is lower by about 3/8” than the left. It appears the right elevator root rib was malformed and I did not catch it before I riveted it to the actuator weldment and control surface. I’ve attached 3 pictures, the ‘Left Side – OK” picture shows the good left root rib and the “Right Side – Bad” shows the malformed right root rib. The “Right Trailing Edge” picture shows how much lower the right trailing edge is when the left is aligned to neutral. I’m sure the right root rib is responsible for the alignment problem.
I should have caught this before I assembled the pieces but I didn’t, I did notice the top and bottom trailing flange on the right root rib were not equal width implying the rib was not positioned properly when formed but I thought as long as there was no flange edge clearance issues when riveted it would be OK. I should have realized the pre-punched mounting holes in the rib web that attaches to the weldment were also shifted. I know the airplane will fly OK with the difference in the trailing edges and the difference will simply manifest as drag but I really think I should replace the rib and get the trailing edges better aligned.
I've sent an email to Kerry Fores (Sonex Technical Support) and hopefully I can get a replacement right root rib otherwise I will just order a new one. Hate to have to drill out the old rib but I really should replace that rib and get the trailing edges aligned.
