This is what I did over the last 3 days with a little work every day. First I bent the tubing for the rudder and I smooshed the top of the 7/8" tubing to 5/8". When I made my elevator and rudder hinges I made them all the same. Looking a little closer at the rudder plans I noticed the bottom hinge tube is a little longer so I made a new hinge. Then I cut the two tube pieces that fit on top and bottom side of it. I decided to fit the hinges to the tail post now figuring it would be easier now than after the rudder is welded together.
I router cut a 7/8" half round grove in a 3.5 inch long 2x2 piece of oak (stair rail material) to use as a drill guide to drill the tail post for the bushing. After drilling the hinge locations on the tail post out to 3/8 I installed the bushing the same way I did on the horizontal stabilizer. When I was fitting the lower hinge I got sloppy and messed up the hinge and the bushing. I was drilling at an awkward angle and elongated the hole on the hinge strap and it messed up the bushing too. I was ticked at myself for being so sloppy so after contemplating walking away for the day I knew it was going to bug me until I corrected it. I considered just drilling for a larger bolt but I decided to start over. I drilled the bushing out and fit a new one and made a new hinge. I was a little concerned about drilling the bushing out but it worked out well and left a nice clean hole for a new bushing. This time when match drilling the holes on the hinge strap I was a lot more careful and used a bushing inside the bushing to first drill the hole. That work much better and I felt better after fixing it. I welded on the "V" supports and filed down to fit the hinge straps.
Rudder Tubes Bent
Using a Bushing Inside a Bushing to Drill Other Side
