Well 3 hrs of this session was finishing up the rudder pedal extensions - so much for my 1.5 hr estimate from last session! I formed the lower doubler that rivets on to the extension by clamping it onto the extension and trimming it down on the 3M wheel to profile it to the extension precisely. Then I layed out the rivet hole patterns in the same. Drilled the holes in the doubler and then match drilled to the extension. Then I layed out the screw holes in the rudder pedals that will attach the extension (3). Drilled those holes. Then it was time to countersink all of the applicable holes in the doubler, the extension (for nutplates) and the screw holes in the rudder pedal. Then I layed out and drilled the lightning holes (2 each). Those didn't come out as symetrical as I'd like but they aren't too bad- used the 3/4" unibit. Then it was deburr - holes and edges and then prep for prime and then prime. Then I riveted the doubler onto the extension, riveted the nutplates onto the extension and primed the parts that won't be exposed once it's riveted together to avoid corrosion. I'm not sure what finish I will put on the final product - if any. The last 45 minutues was putting the Grove fluid reservoirs onto the master cylinder (another Randy L. mod) and started to reassemble the rudder assembly when I ran out of time.
