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Terrences Web Site
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Date: 7-17-2007
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Number of Hours: 2.00
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Manual Reference: 6T3A 7
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Brief Description: Try to eliminate twist in elevator
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I talked to Caleb at ZAC Re: the twist in the elevator. Caleb made several points:
1. When working on new section, it is recommended practice to drill with a #40 and cleco with silver clecos until you are sure everything is right. That way, if things need to be moved a bit, when you drill with a #30 or #20 for A4 or A5 revets, the holes will probably still line up well enough even if the inital drilling points were off a bit (as in causing the twist I had in the elevator).
2. He thought that the twist I saw would cause some handling problems, so I should try to correct it. If I had drilled and clecoed with #40s, I would probably not have any problem. Since I drilled with #30s mostly plus a few #20s, I might have a problem.
3. He said to uncleco the elevator and drill the undrilled-alternate holes with #40 drill and cleco. Then, if the #30 holes for A4 rivets were out of alignment, I should redrill with #20 for A5 rivets. If they still were not adequately round, I should drill new holes midway between the old holes, and (eventually) rivet all the holes. That way, the over-large or out of round holes would not cause a problem.
4. He seemed to think that the idea of using a straight 2x4 on the rudder to hold everything in alignment while drilling the new holes was a good idea.
So, I did as he suggested, see image 1. It turned out that the only holes that appeared to be out of alignment were some #30s in the center ribs. Since those holes are destined to be drilled out to #20s anyway, it is unlikely that I will have to drill new mid-point rivet holes. I put some weights on top of the 2x4 to force the assembly down to the table, but I still had to push down on the 2x4 to hold the top of the elevator flush with the table. I did so when drilling the new holes. I drilled all the available #40 pilot holes and clecoed the assembly together. Because I have only 50 3/32" clecoes, I used 1/8" clecos where I could. I ordered another 100 3/32" clecos from Air Parts, Inc.
I needed to cut some more 2x4 steel
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Elevator bottom with 2x4 and weights
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Elevator top on steel 2x4 rails
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Elevator top on rails with 2x4 and weights
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