Completed the rudder tonight by completing the radius of and closing of the leading edge.
In this step I rolled the leading edge of the both skins to a point where the meet in the middle. This will nest in the trailing edge of the vertical stabilizer. The skins are match drilled, deburred and riveted with blind rivets.
This seemed to be a fairly un-scientific step of the process. The leading edges taper, so they are not the same size radius from top to bottom, however the radius' are formed by duct taping the skins to a broom stick and rolling. You essentially just need to give it a go and see what you end up with. I rolled each three section of each skin seperately and finished them off with a bit of a hand massage until they were happy.
It is difficult to set the clecos because you need to force the skins into postion for the holes to line up. I got to assemble and take apart a couple times because initially i drilled the holes to small for the blind rivets. So the holes got drilled to #30 on the second go round then deburred again. After setting the rivets, I guess I am pleased with the results. It's not perfect but i wouldn't even know where to begin to make it any better.
