Brief Description: Installation of the Upper and Lower Horns.
Bolted the Upper and Lower Horns (WD-1207 and WD-1208, respectively) to the Stabilator Assembly. The head of 1 bolt broke while I was tightening it with a torque wrench. I thought this was going to be a major disaster since the Horizontal Stabilator is pretty much completely riveted. I drilled a pilot hole in the shank of the broken rivet and then used a screw/bolt extractor to gently remove it. The nutplate was not damaged and I was relieved. But, I had to spend extra time on this process.
A worse problem I discovered during this stage. The AN3-14A bolts would not fit in the holes in the Counterbalance Brackets. I had forgotten to final drill #12 the Counterbalance Brackets and the Counterbalance Arm per Step 9 of Page 09-03. Not sure what to do. There is not enought space to use a powered drill. I removed the Arm and clamped it in a vise and final drilled (#12) the 4 holes. However, I still need to figure out how to final drill the holes in the brackets. I tried tap drill bits attached to a right angle screw driver and was able to enlarge one hole to a #12 size. I had to take a break after this and see if there is another (easier) way to fix the problem. Have 3 more holes to enlarge. Needless to say, this delayed completion of the Horizontal Stabilator.
