The final step is rolling the lower leading edge. I thought instead of using the PVC like I did on the other two that I'd clamp the rudder to the bench and use the PVC as a form. The skin here was longer and a bit harder to roll properly using the tools I created without a second set of hands.
With the PVC clamped to the table I was able to manually use it as a form to shape the radius. The skin has some spring back so it needed to be bent past 90 degrees to get it in the proper position. I used 1 inch PVC on the right skin, but I needed to manually bend it with just my hands to adjust the radius to fit the template better.
One the left side I used 3/4 inch PVC and didn't need to do as much adjusting. In the end either one will work.
The results overall were acceptable, but I didn't match the template exactly. It looked close enough though and if the worst case were to happen it would be very easy to drill out the pop rivets and reshape the radius. For now I consider the rudder done, except for the fiberglass ends. I'll defer that work for later.
I'm glad to be finally done with the second build of the rudder. It took longer than expected and I'm sure I overkilled it with my setup, but the TE was reasonably straight and there was no twist. If I had to do it again the only thing I'd do differently would be to use sealant on the TE.
Clamped 3/4 inch PVC down to use as a form.
It's not perfect, but it should clear the vertical stabilizer when installed.
Finished rudder! Fiberglass will be deferred until later.
