Fabricated trim tab horn angle from 0.063". First attempt was bent in wrong direction so had to re-blank and re-bend a 2nd , accounting for about 30 minutes of today's work time.
Cut big "chunk" from my large 0.063" sheet using Olfa score / bend break method Cut 36 X 60 horn blank using reciprocating saw Cut around the tab with band saw Bend in vice over a pice of hardwood with radiused edge Straightened edges with disc/band sander Rounded outside radius of horn with hand file Drilled 1/*8" hole on drill press Drilled 3/32" holes in horn with cordless drill Aligned tab with extended trim motor rod center line on the trim tab Held angle in place on trim tab and match drilled 4 holes Opened up 4 holes to 1/8"
Now that all of the aileron components are fabricated and match drilled I plan to clean the parts and rivet the assemblies together in my next work session. Not sure yet if I'm going to prime since current cold weather does not allow cleaning of the skins outside. May opt to just clean and prime mating surfaces of the ribs and other small components indoors so at least one side of each joint will have extra protection. Even with no primer it is doubtful that corrosion will be an issue on 6061-T6 parts, especially here in Michigan where humidity is not a significant as costal states. Also hope to keep plane hangered reducing the corrosion risk even further.
