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Date:  6-14-2015
Number of Hours:  3.00
Manual Reference:  2.8.1
Brief Description:  It was time to cut out the rudders

I had the lines marked out on the rudders and it was time to cut them off the winglet. The air hack saw was used to cut the glass and then the hand hack saw to cut the foam inside. The bottom just needed a few cuts and the rudders just came off. I cut as much foam out of the rudder wells as I could and then used the chisel to remove the rest.

To run the chisel I just have it 70 degrees to the surface and use a pull scrape method to remove the foam. The foam just balled up and rolls off. I leave it up 1/4” and sand out the deep pockets were the foam rolled out of. It works for me and the sanding goes good with 50 grit and sand in one direction with the paper on the edge of the 1x4”

We had to perform surgery tonight on the Pilot rudder. The bottom foam had been cracked and the glass delaminated in the move from Lynnwood Washington to home. I did a quick fix and now it was time to repair the site. The glass was cut off the foam and the foam cut then it was time to break the injury and remove the foam for slurry mix. Once slurry was on the foam and glass it was time to replace it back between the glass and then it was time for wood splints to stabilize the wound.
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Cutting the foam

Cutting the foam

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Removing foam before sanding

Removing foam before sanding

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Surgery had to be done

Surgery had to be done

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