The horizontal stabilizer from spar is much simpler than the rear: just 3 pieces. I started by trimming off the flange on the inner section of the spar webs. Then I layed out the spar doubler per the plans on the provided .063 aluminum plate. I cut the straight portions of the doubler on the bandsaw. I used my air drill and a small bit to rought in the curved sections and easily broke off the waste. I easily smoothed the curves with a dremel and sanding drum. I bent the outer ends of the doubler with my bending brake. These don't need much of a bend (only 8 degrees). Using the brake, I overshot both ends by several degrees. With a little grunting and cussing, I was able to flatten out the bend to where it's about right. However, I'm concerned that the extra bending has weakened this critical part. I've ordered some replacement aluminum stock from Aircraft Spruce and will make a new doubler.
