While perusing the VAF forum the other night, I found a different way to make rudder stops. It consists of a HDPE plastic fixture bolted to the lower rudder hinge that limits the rudder swing to 35 degrees left and right per Van's manual. Jeff Bordelon of Austin came up with the idea and design. I never really liked the idea of banging the rudder control arms into aluminum angle stops riveted to sides of the fuselage during a control check. Its also much easier to install than riveting and bucking inside the aft tailcone. I ordered a 12"w x12"l x 1/2"t sheet of HDPE from McMaster Carr to cut out my stops.
I modified Jeff's method by sandwiching the 1/2" thick stop between the hinge halfs and then drilled the hinges for two AN3-7A bolts. Jeff had the stop bolted on top of the top hinge half and it was only about 1/4" thick. I think a 1/2" sandwich spreads out the load on the rudder spar more, thereby reducing the stresses. It also should eleminate any bending moment to the hinge. I did have to put a couple of dimple holes on the stop contact faces to allow for the rivet shopheads on the rudder spar.
I'll call Vans to check what they say about this design and method. I pretty much know what they'll say, "Build it per the plans." I can always use their method if they are really against the plastic stop method for a good reason.
Drawing copied to 1/2" thick HDPE plastic sheet to cut out with bandsaw and drill press.
Plastic stop sandwiched between hinge halfs and bolted.
View from beneath the hinge showing the stop and rudder control arms.
