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Safari Helicopter Construction
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Date:  11-18-2006
Number of Hours:  2.50
Manual Reference:  Prints Page 31
Brief Description:  Finished Horizontal Stabilizer

I delayed the final assembly of the stab until I could figure out how to adequately deburr all of the holes that were drilled into the support tube. The deburr tools I used only removed the burr from the outside but not the inside of the tube. Burrs left around a hole in a can act as stress risers and can lead to fatique cracks. I finally decided to use a small diameter brake honing tool on the end of a long extension attached to my drill motor. I removed all of the burrs and a minimum amount of primer. Since other builders have reported loose rivets on the stabilizer, I decided to use stainless steel rivets for extra strength and set the skin to the tube in a bed of sealant to provide more contact area than the curved surface of the tube OD provides. I finished it up by applying sealant to the end cap after riveting in place.
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Finished assembly

Finished assembly

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End Cap in place

End Cap in place

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Sealant added

Sealant added

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