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Roadster's Web Site
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Date: 10-1-2006
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Number of Hours: 5.50
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Manual Reference: 7-4, 7-5
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Brief Description: Assemble Stiffeners & Shear Clips
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Spent the first part of the day deburring the remaining stiffener pieces cut yesterday. Then I assembled and match-drilled the bottom rib assembly and the rudder horn. The rudder horn took quite a bit of time to debur, given it's thickness and curved 3D shape, requiring many of the sheared edges to be deburred by needle files. Once the rudder horn was deburred and assembled with the bottom rib assembly, I countersunk four of the holes per the plans. I then cut, deburred, match-drilled, and countersunk the tiny striker plates. This proved a little problematic, given the small size of the parts. While countersinking, I went a little too deep on the left side plate, because the countersink cage didn't have any support material around the outside corner of the small part, so the cage leaned to one side and the bit removed too much material. (Lesson learned: In the future, chuck the countersink cage in the drill press for these small parts to ensure perpendicular alignment and prevent this problem.) So I will have to order a replacement part from Van's to correct the left striker plate before final assembly. Finally, I assembled and match-drilled all of the shear clip/stiffener assemblies and then mounted them on the spar to be match-drilled tomorrow. Overall, a productive day, but frustrating due to the problem with the tiny striker plate.
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Rudder Spar & Stiffeners
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Fore Side
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Aft Side
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