Elevator mock-up 09-07 to 09-09

The next steps focus on preparing parts of the rudder for final assembly. The first step is to cleco the bottom skins to the ribs and spars. The elevator trim tab connects to with elevator with a piano hinge which needs to be trimmed to size. The piano hinge is clecoed at the pilot holes to the rear spar and the trim spar. Then the spars are match drilled at each hole. Van’s instructs you to use a clamp and cleco as you go to keep the piano hinge straight. I stole an idea from the vansrv14project.uk blog to make a measuring tool to quickly check the distance of flange edge from the piano hinge edge before drilling. I cut two small pieces of sheet metal and double-stick taped a them together with an offset I measured at the pilot hole distance.

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The top skin is then clecoed to the entire assembly. The trailing edge wedge is positioned and trimmed to fit the elevator and trim tab. The instructions ask you to use belt sander to flatten the ends of the TE wedge so that the thickness matches the thickness of the elevator tip fairings. I found this process to be sort of imprecise, but I decided to just sand the aluminum down so that it created a rectangular end with thickness of about 3/32”. I used 3/32” based what I felt was the average thickness of the elevator tip at the end. I will probably add more of a break to keep the skins from lifting from the TE wedge.

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The next step was to match drill the trim close out tabs to the shear clip. I double-sticky taped a rib to the skin to provide some structural support while preforming the match drill.

No pictures, but I began dimpling the counterbalance skins and tip ribs.