The rib layups were trimmed and sanded flush with the outer skin of the winglet and the rudder. The bellhorn cavity in the winglet was opened.
The hinge locations were marked on the winglet and the rudder. The winglet locations had about 0.2" trimmed to allow for the hinge to be slightly recessed. The hinges were clamped in place and a small 0.75" angle clamped on the rudder hing side. The hinges were all aligned using the angle aluminim as a straight edge. Pilot holes were drilled (1/8") and clecos installed to hold the hinges in place. The clamps were removed and the hinge movement was checked with the angle alum still attached to assure that the hinges worked together.
The bottom hinge was shortned about 0.5" on the rudder side only. All of the hinge pin loops remain. This allows the hinge to be placed 0.5" lower than would be required to clear the bellhorn.
The pilot holes were drilled out to 3/16" and AN52510R8 screws were placed in the holes to maintain alignment. When all of the pilot holes were drilled out, nutplates were installed on each of them using flat head rivets to attach the K1000-3 nutplates. I messed up on the lower hinge by placing the nutplates on the wrong side of the hinge face. I left it for the next day to repair.
