Morning of 25 May 04 - Day 2 at the Alexander Tech Center


The general plan for today is to do the same thing to the rudder and elevators that we did to the horizontal and vertical stabilizers yesterday. Well, we didn't get completely done yesterday, but the general plan for yesterday and for today is to cleco everything together, drill everything that needs to be drilled, take everything back apart, and then scuff everything for priming and dimple everything.

The day started with finishing up dimpling the skins from yesterday, so without further ado, here we are:


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This is the dimpler that we'll be using for the skins.
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It's sort of like the Avery C-frame dimpler but with a handle instead of a place to hit it with a mallet.
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I've got the easy job here - just push while Jacob puts the skin in the right place.
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We did the vertical and horizontal stabilizer skins using this dimpler.
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Dad's taken my place dimpling while I wander up the stairs to take a picture.
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Polishing an elevator spar.
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Fluting the ribs for the elevator.
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Jacob's explaining how the rudder will fit together.
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Clecoing the rudder spar to the rib.
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Rudder frame is starting to come together - there are no more ribs, just stiffeners that attach to the skin.
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Drilling the rudder horn.
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Drilling the rudder couterweight.
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Match drilling the couterweight and the couterbalance rib.
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Couterbalance hardware. After this I get to countersink the lead weight.
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Now the rudder horn brace (the thing that looks like a small box) is in there.
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Detail of the rudder horn brace and the rudder horn.
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Drilling/clecoing the horn brace to the bottom rib.
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Inspecting the entire rudder frame. Weird that it's this minimal.
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Clecoing the stiffeners to the inside of the rudder skin.
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Stiffeners are in - this will be the right side of the rudder.
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And here's what it looks like on the outside with all the clecos everywhere.
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Drilling the rudder skin and stiffeners.
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View out the shop door: we'll get to that point eventually!
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Clecoed and drilled left rudder skin.
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Now we're jumping ahead to start drilling the elevator ribs.
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Dad drills - note the block of wood Jacob's holding to hold the bottom piece of metal in place.
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Different personnel, same procedure.
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The wood is there to keep the pressure of the drill from bending the metal down.
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First view of the rudder frame sitting in one of the skins.
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Clecoing the skin to the rudder frame.
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First rudder skin is on - now let's do the second one.
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Clecoing the second rudder skin on.
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The rudder is now together. Now we drill out everything.
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Detail on the rudder trailing edge: this is going to be interesting to rivet.
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The complete rudder! Now we can take it apart.
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Elevator horn and spar on right elevator.
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Not sure what this hand gesture means, but this is the view of both elevator horns.
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Clecoing the elevator parts.
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Detail of the left elevator spar and elevator horn.
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Clecoing the elevator spar to the elevator spar.
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Match drilling the elevator horn and the main elevator spar.
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Deburring the rudder skin.
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Dad uses scotch-brite on the inside of the rudder skin for priming.
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Rudder parts ready to be primed.
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Chamfered edge on the rudder. This doesn't show up real well, but it's where the rudder skin meets the couterbalance skin.

Well, it's time for a lunch break again. Today for lunch we went to the Bank Street Cafe in downtown Griffin - highly recommended. Try the Buffalo Chicken Wrap or the French Dip.

After lunch, we'll keep working on the elevators and start the trim tab.




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