After a long hiatus I got back in the shop today and got some good work done, as well as encountered a potentially serious problem.
My last post I had separated and edged elevator hinge doublers E-00001A and B. These are paired up with E-610PP and E-611PP to reinforce the elevator hinge attach point. Well the E-00001 parts have four additional pre punched holes than the spar or E-610 or 611. Then I remembered that parts that have a number of 00001 are usually service bulletin parts that have been added to address problems that have arisen. I checked Van's website, and sure enough, Service Bulletin 14-02-05 covers installing the hinge doublers due to possible cracks in the elevator spar. Luckily we later builders get the benefit of earlier builders discoveries.
On to the problem. After match drilling the spar and hinge plates, you match drill E-707 tip rib and E-704 counterweight rib together back to back, the match drill to the spar. No problem. Then remove 703 and 704 from spar (still attached to each other). The next step is to cleco the counter weight skin E-713 to E-704/703 with the counter weight sandwiched in. The counter weight has to be filed quite a bit before the E-713 skin will line up with the rib holes on both sides. After getting the counter weight filed enough to fit the skin on, I noticed a different alignment problem. In the the second pic below you can see how 703 on top is connected to the counter weight rib 704 below, with the skin 713 wrapped around (the counter weight is on the bench). In pic 3 you can see that with the skin lined up on 704, the holes are way out of alignment for 703. This would be the top of the right elevator on the finished plane. the bottom holes line up perfect on both ribs. As I was writing this I went back and double checked the ribs. It appears rib 704 needs a bit of fluting. That will have to wait until I am back from my 3 day tomorrow, as I have consumed an adult beverage. There is no altering of metal after a beer.
