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Kurt Haller RV-9A
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Date: 1-14-2007
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Number of Hours: 7.25
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Manual Reference: 6
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Brief Description: Epoxy filler; elevator control horn holes
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Used Dremel w/flexible paper sanding disk to take down most of the Poly-fiber Superfil epoxy daubed into the left elevator LE repair and into the blind rivets on elevators, rudder, and trim tab.
Masked off the areas where the Superfil was, and used 180 and 220 grit paper in a random orbit sander, then hand sanded with 320, 400, 600, 1500 SiC paper.
Fit the elevators one at a time to the HS and used a 1/4" OD x .140" ID nylon tube as a bushing to mark the horns with a #28 drill. Finished thru drilling w/#28 (slow speed electric drill and Boelube used on the steel!) The enlarged hole w/#19, #10, and then D-sized drills. Deburred the hole after each size so next drill wouldn't grab and self feed so readily.
Finally reamed hold to final size with a 0.249" reamer. Re-hung the elevators and test fitted the AN4 bolt. Needed one washer (besides the large fender washers) on the rh side, and I sanded that one down a bit. Fabricated a washer wrench of sorts out of scrap Alclad to get the rh side washer in place.
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