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Dave White RV-7 Build Site
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Date: 5-31-2011
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Number of Hours: 5.50
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Manual Reference:
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Brief Description: Rolled the Rudder Leading Edge - *eventually*...
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Well, this was significantly more difficult than I'd expected - and the plans/other builders' reports had suggested it wouldn't be straightforward.
The leading edge of the rudder aerofoil is formed by rolling two tabs of the skin together so that they overlap, and the plans say that to do this you use a 1/2" or so diameter rod - in my case, I chose a broomstick - and duct-tape it to the edge of the metal and then roll around the rod uuntil the metal curves and the two parts meet in the middle.
Most builders say that it takes much perseverance, and they're not wrong. The upper and middle portions of the LE were OK, but required a fair amount of "fettling" (a good Northern engineers' word!) before the pre-punched holes lined up for clecos to be inserted.
The lower section, though - where the rudder LE is at its widest - was a complete swine. This was partly because I took the plans at their word, and rolled each around the rod at the tip of the metal. This ended up over-bending the metal at the point where the sections join, and under-rolling it - that is, giving it too shallow a curve - close to the spar. In hindsight, I should have bent the skin against a former held up firm against the spar first, in order to give the required steep curve, and then rolled much less at the edge to give a more shallow curve where the two parts meet.
Because I had over-rolled it initially, it took absolutely ages to re-form the curve and get it right. I've claimed 5.5 hours, but it probbaly took at least half as much again in reality if you include the wasted time thinking about it, walking away and muttering, and generally being frustrated!
However, it's turned out OK, and most importantly it has given me a much needed lesson for the 6 other surfaces in the kit where the technique is used. We'll see how that works out, and there won't be long to wait since the next component is the right elevator, on which the technique is also used.
Note that the 3 images below are in reverse order of time.
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Finally!
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Unbent lower tabs, and rolled centre portion
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Preparing to roll centre portion.
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