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Patrick Kelley (Flion)
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Date:  10-1-2011
Number of Hours:  6.00
Manual Reference:  None
Brief Description:  Fabricating rudder trim tab, part 1

After butchering my rudder the other week, I've finally gotten the materials I need to finish the trim tab, mostly. First I cut a section of hinge, figured the rivet spacing, and pre-drilled the holes. Then I took one section and clamped it in place on the rudder and drilled it. Next, I added the trim tab. I laid a straight edge along the hinge line to the bottom of the rudder and used it as an aliignment tool as I drilled a hole for the hing pin in the bottom three ribs. I'll figure out how to secure it later but for now I just have a long piece of hinge pin sticking out the rudder bottom. With the tab hinged, I could swing it to the right with the tab skin under the rudder skin and mark where it would have to be cut to prevent interference at full deflection. Then I ran down to Jack Keegan's hangar and used his band saw to cut some foam pieces to be used for the ribs and spars in the tab area. I fabricated a control horn from some 1" angle and adjusted the foarm to fit around it. Then I sanded the angel at the leading edge of the tab. It's not shown in the pictures but the ribs for the rudder opening are made up as well but I am waiting to route the pushrod before I finish the rudder spar. Along with that, I have to releive the right rudder skin for the pushrod and control horn and make a small fairing to cover them up.

In order to finish up, I will have to dimple and rivet the hinge halves to their respective surfaces and then glue in the foam bits, relieveing them to fit over the rivet shop heads. Then I will have to seal the exposed foam and fill any gaps or low spots. Finally, I will have to make sure the hinge pin opening is still there, or re-drill if it has been filled in, and then install the hinge and some kind of keeper. After that I can hook up the pushrod and address the wiring.
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