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Daniels Web Site
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Date: 5-20-2012
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Number of Hours: 5.25
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Manual Reference: 6-5 / 6-6 / 6-7
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Brief Description: Rudder Final Assembly
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"After a lunch break, I continued to put in a pretty full day of work on the rudder. Don't underestimate the amount of work that goes into this thing. I now have almost as much time in the rudder as I do the VS. I got a bunch done today!!! here is the laundry list of tasks done after priming earlier this morning.
- Skin Stiffeners final riveted to the Left and Right skins. The back rivet plate that I imbedded in my one work bench was a total life saver here. I'll have to add this to my list of ""Best of the Best Tools""! I can thank Matt Lorenz for the idea and the source of the large 12""x18"" steel plates. I actually feel a little bad for the folks who struggle around with those little crappy backrivet plates supplied by the aircraft tool shops. An astute observer will probably notice that the aft most rivets are slightly over driven. This was done intentionally to provide stiffener / rivet clearence when the trailing edge is mated.
- Started riveting the rudder skeleton. First were the upper two spar reinforcement plates & nut plates. All went well here; personally, I didn't like the rivet call out in the plans the (-5) were too long but the (-4) were a tad too short to make a good shop head. Well, in denial, I went ahead and used the -5s bent two over and had to replace them but over all, I was left with some pretty tall but good shop heads.
-Next came bottom reinforcement plate, shim, bottom rib, nut plate and rudder horn combo joint. Here again I was troubled by the rivet call out in the plans. The plans call for a univeral head -7 rivet but that was too short in my opinion as this is a very critical / high stress area.. I tried the - 8s and they were too long and would have bent over. I didn't want to play russian rulet; try setting rivets in such a critcal area just to get a look-see and end up drilling them out. I went ahead and shaved 1/32"" off of the -8s, essentally making a AN470 4-7.5 rivet. these came out PERFECT.
- Finally I match-drilled the counterweight to the counterweight rib, d
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Stiffeners Rivet
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Custom Rivets
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Rudder Horn Malfunction- Junction Riveted w/ Custom Rivets
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