I constructed a pair of jigs to reduce the risk of dropping the rudder while I inserted the nose skin between the rear skin and thespar. The angle for the jig was calculated from dwg.. 6-T-4-6 for the bottom rib:
tan φ = (107/2)/(595 + x) = 5/x,
where x is the length of the base projected to the intersection with the hypotenuse. Solving gives
x = 61.34 mm, and
φ = 4.66°
I cut the ends of some ~6” wide pieces of 3/8” plywood from the shipping crate at ~4.5°, screwed them to two short 2x4 lengths, and screwed the 2x4 to the table to support the rudder. I padded the rear edge of the rudder with rubber drawer liner material.
Photos 1, 2, & 3 show the rudder held in vertical position with the nose skin inserted. I suspect that jigs of this type can be used profitably throughout the construction. The jigs took about 1.5 hrs to get right. Trying to measure the 4.5° with my speed square resulted in angles about 3° too large. I used my construction angle protractor to remeasure the angle and recut the jig.
