Made a jig to keep the R-916 (AEX trailing edge) perpendicular to the microstop csk from a block of maple. Tilted the blade on the table saw to 11.5 deg with the SmartTool, ran the block thru on its edge. Reset the rip fence and blade height and ran it thru again with block on it's face. Then jointed the face until the top of the block was fush with the AEX matl.
With a #40 hole in the maple to provide space for the pilot, carefully crept up on the microstop setting, then rattled off 92 perfect csks (46 each on both sides of the wedge.
The thru hole winds up bigger than #40. Hope this is OK...the dimples from each skin nearly touch, so the rivets should be well-confined when they're set.
I still may be a couple thou too shallow. (You can always take more off--it's hard to put it back on.) So I partially assembled the rudder again to check the trailing edge fit in the AEX csks. Gonna sleep on it and inspect it in full daylight before calling it done. The skins still oil can...aft rivet holes on top and bottom ribs aren't dimpled yet--bought a tool from Cleaveland to take care of that, eta 11 Sep. Also, the dwgs seem to show the counterweight skin R-913 goes UNDER the main rudder skins R-901-L,R. Is this right? It seems to me the edge shouldn't face the wind...and the main skins would fit the skeleton underneath a lot better. Better check the internet...
