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Date:  8-2-2015
Number of Hours:  4.90
Manual Reference:  Step 4
Brief Description:  Mounting Elevators on Canard

Resolved template issues. Still a bit miffed.

Checked alignment of Canard and Elevators using the angle template and shining a light from above to see where the interference is. I left the TE a bit rough so there is fat to play with. I adjusted the Canard TE to suit with sanding board. Ended up with 15 degrees TE up, at which angle the gap is mostly eliminated. Would have been easier if the TE of the Elevators had been at the edge of the table, but I was worried about dropping them. Canard set off the table on blocks may have helped.

Bondo'd on L templates. Outer ones fell of, so refitted with 5-min.

Placed an NC-3 Hinge on the Hinge pin outboard of the tip and marked the profile of where the socket needs to be cut in the canard, looks like about 9-39mm from the LE of the Elevators. Seems to agree with the full size drawing. Wondered if I could leave the NC-3 fitted and just rotate them down into the flox, but it would need another 15mm of skin cutout, so I'll do it the plans way.

Marked the B.L. position of the cutout from the hinge. Marked the F.S. of the cutout from my Elevator LE measurement.

Tried a few methods of cutting the hinge slots. Best seemed to be to make a plunge cut with a straight 1" cutter on the multitool, then do the ends and expand it with a 1/16" tugsten cutting tool in the dremel. Incidentally, my Ozito 'dremel' has crapped its bearings, the same way the Dremel did, so now I am calling a Duratec tool from Jaycar a 'dremel'). This only goes down about an inch, followed up with a 1/4" drill bit with the end rounded off in a cordless drill.

Had to use a 12" long bit to do the slots next to the offsets, didn't work near as well.

Floxed NC-3 into canard. Plans method didn't work very well at all, flox just spludged everywhere when I sank the hinge in. Ended up putting the NC-3 into position, then injecting flox using a 100ml syringe Drew Chaplin gave me, that I haven't been able to source here, so cleaned it very carefully, as it is the only one left.
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Lining up the jigs

Lining up the jigs

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Hogging out the hinge slots

Hogging out the hinge slots

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2 x NC-3 in place, injecting flox into the 3rd

2 x NC-3 in place, injecting flox into the 3rd

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