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Damiens Web Site
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Date: 4-16-2017
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Number of Hours: 6.00
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Manual Reference:
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Brief Description: Rudder - cont.
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Fabricated R-717 shim and R-716 rudder bottom attach strips from supplied strip of AS3-032X1 1/8X40 T3 aluminum using the specifications on the plan drawing. Trimmed R-710 rudder horn brace as per plan drawing. Radiused the top edge of R-405PD as indicated on the plan drawing so that it would fit properly with R-704 rudder rib. Gradually enlarged the center hole of the forward flange on R-704 rudder rib from #30 to 3/8" using, in order, #27 bit, #21 bit, #19 bit, #12 bit, 1/4" bit and finally very carefully using the unibit to get to the final dimension of 3/8". Clecoed R-704, R-405PD, R-710, R-717 and three platenuts to the R-802PP rudder spar. Enlarged the holes that attach R-703 tip rib to R-802PP to #30 and then removed R-703. Clecoed R-713 counterbalance skin to R-703. Used the fluting pliers to adjust the forward flange of R-703 so that the holes would line up with the holes in the forward face of R-713. Drilled all holes that attach R-713 to R-703 to #40. Drilled all pre-punched holes in R-802PP rudder spar to #30. Drilled all holes that attach R-710 rudder horn brace to R-405PD and R-704 to #30. Clecoed spar assembly to R-801PP rudder skin.
At this point I noticed that the trailing edge of the skin was pillowing slightly due to being under bent.
Clamped the R-716 rudder bottom attach strips to the R-704 ribe. Match stilled R-716 and R-710 using the holes in R-801PP skin as a guide. Drilled all remaining holes in R-713 and R801PP to #40. Marked and removed the skin. Placed the skin back in the bending jig and applied pressure until additional bend was achieved. Reattached the rudder substructure to the skin and again checked for alignement. The pillowing was gone. Completely disassembled the rudder assembly and began preparing for deburring, dimpling and priming of the parts.
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Fabrication results
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final drilling the assembled rudder
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