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Zenith CruZer & Sonex Logs
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Date: 4-11-2010
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Number of Hours: 4.10
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Manual Reference: SNX-T14 / -T01
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Brief Description: Misc Tail Work
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Started the day by continuing to finesse the right side curved tail fairing. This was not strenuous, but just took a lot of time to smooth it out, adjust the angle of the attach angles, smooth it out some more, etc.
Next I fabricated the smaller of the 4 tail fairings. These just fill in 4" worth of perfect 90 deg angles between the back edge of the horizontal stab and the vertical stab. Pilot drilled to 1/16" as these only take self-tapping screws, so the final holes will be enlarged to 5/64".
I then spent the next major block of time trial fitting the vertical stabilizer tip fairing. I had previously test-fit it when I first made the vertical stab back in 2008, but never drilled it. Re-fit it today. Adjusted to fit better to be in alignment with the vertical stab now that it's on as well as lineup with the centerline of the fuselage. Drilled and cleco'd.
Next, I had to mark it for trimming the back portion of it that resides above the rudder. Since part of the fairing skin fits inside the vertical stab, the back angle of it would then conflict with the rudder. You must notch the back portion 3/4". Used a cutoff wheel in the Dremel tool to make easy work of trimming it. Followed up with a file to have a nice smooth, straight line on it.
The finishing part of this was to drill-out 3 rivets on the back side of the upper tip rib attachment in order to fit the fairing tip rib that will fit up inside the back half of the fiberglass tip. Marked, clamped, and drilled to final size.
Lastly, test-fit the rudder to check the swing angle. The first time I did this a few weeks ago I still had some of the (mistakenly used) domed rivets in the rudder stop plates. I had drilled out and replaced them with the called-for flush rivets. I'm within about 1-2 degrees of proper swing arc, but my plastic angle finder is a bit too flexible at the near-180 degree setting. I'm going to find and borrow a better quality angle finder to ensure I don't go overboard on this setting.
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Upper fairing in place
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Vertical-to-Horizontal Fairings
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Checking Rudder Swing Angle
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