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Aug 6, 2019 - Slowly trimming away more material. The 'saddle'
(as
the plans call it) is getting close to fit.
Aug 6, 2019 - Trimmed away enough material to enable the elevator to be attached.
Aug 7, 2019 - Removed elevator, and trimmed another 5mm from the rudder.
Reinstalled elevator. Not only does rudder need trimmed to clear the saddle,
but
must be cut back to clear elevator when rudder swings.
Aug 9, 2019 - Gary Reynolds lending his sheet metal expertise to the
rudder trimming process. We (Gary) has spent several hours and made
several
cuts to gradually shape the cutaway.
Aug 12, 2019 - Taped a piece L-angle to the level line of the elevator.
Aug 12, 2019 - Using engine hoist to lift the elevator.
Aug 12, 2019 - Angle finder attached to the L-angle on the elevator,
Indicates 32 degrees up angle.
Aug 12, 2019 - With the elevator up at 32 degrees, the right side of the
rudder is now trimmed enough to now contact. Final trimming is needed.
Aug 15, 2019 - New digital level to give more accurate reading.
Aug 15, 2019 - Made paper template of right side to transfer to left side.
Aug 15, 2019 - Rough cut line based on template.
Aug 15, 2019 - Put the turtle deck back on to check fit of fiberglass saddle.
Will need to secure it in place before make final trim to rudder.
Aug 23, 2019 - Rough clearance at this point. Need to attach the saddle
to get an accurate measurement on final clearance.
Aug 23, 2019 - Using scrap L-angle to estimate bend angle needed to
match the side of the saddle to the surface of the horizontal stabilizer.
Aug 23, 2019 - This appears to be close to needed angle.
Aug 24, 2019 - The plans call for brackets of 100mm bent to 60 degrees.
Aug 24, 2019 - Again some of the plan dimensions turn out to be "suggestions".
Aug 24, 2019 - After more tweaking, the required angles are more like
55 degrees in order to get a flat surface.
Aug 24, 2019 - A view of the saddle resting on the horizontal stabilizer showing flat contact.
Aug 28, 2019 - After deciding that using standard L-angle bent to 55
degrees would make riveting very difficult, I did some research online.
Aug 28, 2019 - One builder made his own oversized tabs.
Aug 28, 2019 - After making several sets of different sizes and material
thickness, I settled on these made from .025 inch material.
Aug 28, 2019 - Made first 90 degree bend using vice and rod for a
1/8 radius bend. Final bend will be made by hand when fitting the saddle.
Aug 29, 2019 - Trying to create a smoother cut line.
Aug 29, 2019 - John Rothrock creating a layout to check turn
angles
of the rudder. Looking for 20-22 degrees each direction.
Aug 30, 2019 - Hopefully 'final' trimming done to the right side of rudder.
Aug 30, 2019 - Paper template from right side of rudder to transfer to left side.
Aug 30, 2019 - Additional trimming needed based on template.
Aug 31, 2019 - Found it necessary to round off edges of upper hinge
to allow the rudder to swing the full 21 degrees needed
Aug 31, 2019 - Rudder now able to reach full deflection. Rudder stops
will be riveted to the fuselage at the point of contact.
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