The bottom hinge was carefully lined back up and the 3/16" holes drilled using the holes in the winglet rib, that were drilled the day before, as a guide. The nutplates were installed correctly. All of the hinges had nutplates installed and they were reattached to the winglet. The angle aluminum was reinstalled to check the alignment, which checked out good.
The rudder was set in place and held by some clamps. The hinge locations were carefully marked on the rudder. Drill points for the pop rivets were marked. The rudder was removed and set on the table. The rudder side of the hinges were clamped in place carfully aligning with the measurements taken previously. One 1/8' pilot hole was drilled in the top and bottom hinges. They were installed with clecos to hold them in place. The rudder was installed back into place and was checked for clear movement. For the most part it was good. There was a rub on the internal bellhorn against the inside skin of the winglet as it was starting to move out. The bellhorn corner that was rubbing was sanded down to fix this. The bellhorn was also hitting some excess foam in the winglet that prevented the rudder returning to the home position. The foam and micro were removed to eliminate the interference.
The rest of the rudder pop rivet holes were drilled and clecos added. I have ordered the pop rivets so they will be installed later.
Similar to the direction of Wayne Hicks, I removed a small section of the wing skin right about the rudder cable conduit as it approaches the bellhorn. This will allow the space to be increased to assure that there is not any interference with the cable thimble attachment to the bellhorn.
