Left Elevator - 2 hours I worked more on the problem with the control horn not lining up properly on the elevator. Here is Van's response:
"You may find that it will fit better if you remove a little material from the inboard end of the spar web. If that is contacting the radius of the bend in the horn it will prevent the horn from moving aft or outboard enough. Some slight modification of the bend in the end rib may also improve the fit.
You can check the fit of the horn on the other elevator also (inverted) to see if there is a difference in the horns, or if it is something to do with the rib/spar junction."
The response on VAF was that others experienced the same thing and that they tweaked the end rib, which is what I did. Here's a pretty good picture of the problem area. Note that the rib doesn't sit all the way down in the "valley" of the control horn.
I cut a few pieces of wood and clamped everything to the table like so. I tried whacking it with my mallet, but ended up using the rivet gun with the flush set - that worked really good for tweaking the bend.
The holes started lining up better in the control horn and the rib / spar.
But the holes for the spar to rib were way off after this tweaking.
I decided to re-drill them instead of trying to force everything into place. I re-drilled and made a small doubler that will sandwich the rib flange with the oversize holes, so I think it will work out fine. The rib with the figure-8 holes:
Drilling the doubler:
After that it was time to disassemble and debur. I started deburring the skin.
