Brief Description: Match drilled rudder enclosure for pop-rivets.
Today we decided to match drill the rudder bottom enclosure for the countersunk CS4-4 pop-rivets. I carefully marked the spacing by drawing a line 10/32" from the skin edge and spaced eight holes at 2.46" between the holes. I used my Makita cordless and drilled using a #30 drillbit. It came out nicely.
A tech counselor came by and we went to another hangar to look at how another builder had strung the wire into the enclosure. The builder had slotted the forward end to quickly slip the wires down into the hole that he had drilled. I did not want a slot because it would weaken the enclosure. He had used a rectangular 4 wire molex connector. I planned on using circular molex connectors so that I could pull each wire separately through the snap bushing. I originally had drilled the forward hole to hold a 3/8" ID snap bushing but enlarged the snap bushing to 1/2" ID. I also raised the hole another 1 1/2" higher, so that the wires in the vinyl tube would be in a "Z" shape to prevent fatiguing the wire from rudder movement in the short span between the aft bulkhead and the enclosure. I'll glass over the old hole later.
