Brief Description: Trim Tab Hinge and Elevator Cut-out
Cut an 895mm length of hinge on the power chop saw. Had hinge clamped to fences on both sides an cut VERY slowly, taking shavings rather than chunks. Pressed trim tab top skin down to top flange using steel bar then slid hinge underneath. Match drilled hinge. Deburred both pieces then cleaned with Simple Green and new abrasive pads which worked very nicely.
Tip: The hinge leaf with the outer-most knuckles should be attached to the elevator, not the trim tab. This configuration will ensure that the safety wire or pin used to retain the hinge pin will not rotate into - and possible interfere with - the elevator trailing edge.
Marked out the trim tab opening on the elevator. Used 2-3/4" hole saw to create four access holes for snips which were used to remove material. Created radiused relief in each corner with rat-tail file. Filed straight surfaces smooth. Cut down left side elevator rib to match opening.
Discovered that one end of the elevator cutout channel - made back on 2/28/11 - was 2mm too wide, explaining why it seemed oversized on the inboard end when doing a trial fit. Bent up a new channel that was the same width along the entire length but almost 1mm wider than spec.
