Brief Description: Match drilling the elevator horns
I took the right side off so I could drill the left horn. First I duct taped the left elevator in trail. Then I pulled out the drill bushing that acts as drill guide protecting the center bearing in the process. The plans say the bushing may have to be filed down to fit into the bearing, and sure enough the bushing was too big. So I chucked it into my drill press and began sanding and filing it down. It took more time than I thought it would because I only filed a little at a time as I didn't want to take too much off. Eventually I got it to fit through the bearing and matched drilled the left horn, I then took the left elevator off and mounted the right one and repeated the match drilling process. I then re-mounted the left side and attached the horns to the center bearing. I then determined that the right horn was the most aft and drilled the push rod attach hole into that horn, The left horn needed to now be match drilled to the right. To insure that the holes were drilled perpendicular to each other, I had to make a drill guide block that was exacty the same thickness as the span wise distance between the 2 horns. I clamped the block in between the horns and then match drilled the left horn using the right horn and block as a drill guide, I had read that some guys had lots of trouble here, but mine turned out fine and the whole process went exactly according to the plans.