I used the pneumatic squeezer to dimple the holes in the rudder for tip attachment. I had to remove the counter weight to get at two holes on each side. Also, had to use a pop rivet dimple tool to get the very last hole on each side on the aft end. Used a countersink bit in my cordless to c/s the holes in the fiberglass tip. I tested the deburr tool and the c/s bit on some scrap and seemed like the c/s bit did a better job. I sanded the joggle area on the tip and also sanded the mating area on the inside of the rudder. Next, I mixed up some West Systems resin and hardner. Used 2 pumps of each, but later discovered that I could have used only 1 pump of each—had plenty of excess left over. I also added some flox to the mixture to thicken it up. First, I wet some glass that was laid over the foam block on the VS cap, then moved to the rudder tip. I spread the mixture using a popsicle stick and clecoed the tip to the rudder—then began installing CS4-4 rivets. I dipped each rivet in the resin goop before inserting and pulling the rivet. I used a shorter monel rivet for the very last hole on the aft end. The 4-4 was hitting the opposite side and I was afraid it might sit proud. Took a credit card and wiped the excess that squished out. Cleaned up everything as best I could with Acetone. By the time this was done, the mixture left in the plastic cup was solid—very hot, but solid. Squeezed the plastic cup and the solid chunk popped out-good, maybe won’t have to buy more of these.
