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SEAN'S WEB SITE
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Date: 3-3-2007
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Number of Hours: 7.00
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Manual Reference: Sec. 6-4, DWG 7
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Brief Description: Prepped Rudder Skeleton
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I clecoed the bottom rudder rib to the rudder spar and match drilled the center bolt hole to 3/8". I then fabricated a 3-1/2" X 1-1/8" shim from a strip of .032 2024-T3 ALCLAD aluminum. I clecoed the rudder horn to the spar and back drilled the #30 holes in the top of the rudder horn, using the rudder spar as a guide. I then clecoed the spar, rudder horn, bottom rib and slipped in the shim that I had fabricated and, using the predrilled holes in the spar, I match drilled the entire assembly. I then removed the rudder horn assembly and clecoed the three reinforcement plates to the spar and final drilled them with the spar.
Eileen marked the excess material lines on the rudder horn brace and used wiss snips to cut away the excess material from the horn brace. I then used the Scotch-Brite wheel to deburr, smooth and radius the rudder horn brace. I fluted the couterbalance rib and the rudder tip rib and clecoed them to the rudder spar. I then match drilled them with the rudder spar to #30. I clecoed the counterbalance skin to the counterbalance rib, tip rib and rudder spar and match drilled to #40.
Using two strips of .032 2024-T3 ALCLAD aluminum, Eileen measured, marked and cut the two bottom attach strips. I the deburred and radiused the strips with the Scotch-Brite wheel. I reassembled and clecoed the entire bottom rib and rudder horn assembly to the rudder spar. I used cleco clamps to hold the bottom attach strips to the bottom rib. I then match / final drilled the entire assembly. I did not like the way the rudder horn brace turned out. After final drilling the holes seemed too close to the edge of the material. Being a perfectionist, I will be replacing and redrilling the rudder horn brace.
With all ribs, spar, and counterbalance skins in place, I clecoed both rudder skins to the skeleton assembly. I then inserted the trailing edge strip between the trailing edge of both skins and clecoed it in place. I then final drilled all skin to skeleton / trailing edge holes to #40.
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