Entries for: Empennage - Elevator
| Entry Date: Wednesday, Jul 13, 2005 (details) |
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| EMPENNAGE DONE!!! |
| Empennage
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| Elevator
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| 0 hours
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YAY!
(Oh yeah, and congratulations Ian... newly minted CFI extra-odd-inare)
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| Entry Date: Sunday, Jul 10, 2005 (details) |
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| Rivet the Trim Tab Hinges |
| Empennage
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| Elevator
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| 1.5 hours
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Riveted one half of the trim tab hinge to the elevator. (Except for outermost hole at the right end of the aft partial spar as this will hold the hinge pin retainer)
Riveted the second half of the hinge to the trim tab.
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| Entry Date: Sunday, Jul 10, 2005 (details) |
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| Position and Drill the Trim Tab Hinge |
| Empennage
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| Elevator
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| 2.5 hours
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Positioned the trim tab hinge and drilled the index hole (maintaining spacing/margins). Then aligned and drilled the index hole on the elevator.
Drilled the two alignment holes on each end of the hinge halves.
Drilled all remaining holes along both sides of the hinge. Cleaned and deburred all holes.
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| Entry Date: Thursday, Jun 30, 2005 (details) |
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| Rivet the Elevator Hinge Halves to the Elevator |
| Empennage
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| Elevator
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| 3 hours
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Finished riveting the second half of the hinge to the elevator.
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| Entry Date: Wednesday, Jun 29, 2005 (details) |
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| Rivet the Elevator Hinge Halves to the Stabilizer |
| Empennage
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| Elevator
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| 2 hours
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Riveted the stabilizer-side halves of the hinge in place. Except: both rivet holes inboard of the outboard hinges for the hinge pin retainers.
Followed typical riveting patters being careful to use different length rivets for various thicknesses.
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| Entry Date: Saturday, Jun 25, 2005 (details) |
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| Drill the Final Hinge Alignment Holes and Drill Remaining Holes |
| Empennage
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| Elevator
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| 3 hours
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Lifted the elevator upward with each hinge held in place by a cleco to finalize alignment.
With the elevator held up drilled one stabilizer-side hole at each end of each hinge (#40 so we can drill up later and adjust).
Drilled all remaining holes to #30's. Also drilled up any #40's to #30's.
Removed all cleco's, seperated, cleaned and deburred all pieces.
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| Entry Date: Saturday, May 14, 2005 (details) |
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| Rivet the Trailing Edge Joggles |
| Empennage
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| Elevator
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| 1.25 hours
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Used long-set epoxy, straight-edges, and clamps to set the trailing edge joggles before riveting.
Riveted both sections.
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| Entry Date: Monday, May 09, 2005 (details) |
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| Rivet the Lower Skins and the Control Horn to the Forward Spar |
| Empennage
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| Elevator
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| 2.25 hours
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(Not complete)
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| Entry Date: Saturday, May 07, 2005 (details) |
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| Rivet the Forward Spar to the Ribs |
| Empennage
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| Elevator
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| 0.75 hours
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Replaced the forward spar and realigned with each rib. Riveted in place using pop-rivets.
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| Entry Date: Wednesday, May 04, 2005 (details) |
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| Rivet the Lower Skins to the Aft Partial Spar and Ribs |
| Empennage
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| Elevator
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| 3 hours
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Removed the spar and hard riveted the first three locations on each rib.
Finished the remaining holes with pop-rivets.
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| Entry Date: Sunday, May 01, 2005 (details) |
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| Rivet the Tip Ribs to the Outermost Ribs |
| Empennage
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| Elevator
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| 1.75 hours
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Positioned the Tip Ribs (with their doublers) against the outer ribs and riveted.
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| Entry Date: Saturday, Apr 30, 2005 (details) |
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| Rivet the Ribs/Spars of the Elevator and Rivet to the Lower Skin |
| Empennage
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| Elevator
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| 5.4 hours
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Reassembled the elevator ribs and spars level on the table. Riveted the inboard ribs to the aft partial spar and then Ribs C and D to the aft partial spar.
Riveted the rib/control horn stiffeners to Ribs A and B.
Riveted the upper skins to the ribs in this order: The overlapped skins to Ribs A and B. Starting at the aft end of the server cutout riveted each rib fore-aft.
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| Entry Date: Thursday, Apr 28, 2005 (details) |
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| Rivet the Trim Tab |
| Empennage
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| Elevator
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| 2.75 hours
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Riveted in this order: Trim tab ribs to the upper surface. Control horn and its corresponding ribs to the lower skin. And then all remaining holes.
Glued and clamped the trailing edge and let dry overnight. Finished riveting the trailing edge.
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| Entry Date: Sunday, Apr 24, 2005 (details) |
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| Rivet the Elevator Spar Doublers and Attach Angles/Control Horn |
| Empennage
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| Elevator
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| 2.5 hours
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Riveted the three doublers to the main elevator spar.
Also riveted the attach angles to their respective control horns.
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| Entry Date: Saturday, Apr 09, 2005 (details) |
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| Clean, Deburr, and Corrosion Protect the Horizontal Stab, Elevator, and Trim Tab |
| Empennage
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| Elevator
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| 12 hours
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Started by deburring all ribs, spars, skins, and misc. parts to prepare for corrosion proofing.
Scrubbed all pieces with Alumaprep/Scotchbrite and dipped (or brushed) in Alodine.
After everything dried overnight we painted all parts with Deft primer.
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| Entry Date: Sunday, Apr 03, 2005 (details) |
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| Position and Drill the Control Horn |
| Empennage
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| Elevator
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| 1 hours
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Drilled through the upper skin with a #30 at each of the six rivet locations and cleco'd.
Turned the assembly over, positioned the control horn along the drawn centerlines and drilled with a #40 bit.
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| Entry Date: Sunday, Apr 03, 2005 (details) |
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| Position and Drill the Ribs and Skins (Trim Tab) |
| Empennage
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| Elevator
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| 1 hours
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Aligned and drilled the rivet lines through the skin into the ribs.
Marked out the two lines and future rivet placements that will hold the control horn in place.
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| Entry Date: Friday, Apr 01, 2005 (details) |
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| Fabricate the Control Horn and Counterweight Arm (Trim Tab) |
| Empennage
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| Elevator
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| 0.5 hours
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Fabricated the trim tab control arm from aluminum "tee". Cut the basic shaped and then filed/sanded it smooth.
Drilled the rivet holes that will attach the trim tab counterweight arm. Also drilled out the #10 hole that will hole the pushrod bolt.
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| Entry Date: Thursday, Mar 31, 2005 (details) |
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| Make the Trim Servo Cutout |
| Empennage
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| Elevator
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| 0.75 hours
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Marked out the placement for the trim servo cutout and drilled out each corner.
Rough-cut the remaining skin with the Dremel. Deburred all of the edges and corners and cut out the notch for the wiring harness.
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| Entry Date: Thursday, Mar 31, 2005 (details) |
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| Position and Drill the Tip Ribs |
| Empennage
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| Elevator
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| 1 hours
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Positioned the tip ribs inside the skins. Clamped the ribs and flange reinforcements in place and drilled the rivet holes.
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| Entry Date: Sunday, Mar 27, 2005 (details) |
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| Install Flange Reinforcement and Mark the Hole Positions on the Tip Ribs |
| Empennage
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| Elevator
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| 0.5 hours
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Cut four 10 inch pieces of angle for the flange doublers using snips (would choose to use a saw in the future). Deburred and straightened the edges.
Fit the pieces along the flanges of the tip rib and marked the rivet holes.
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| Entry Date: Saturday, Mar 26, 2005 (details) |
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| Position and Drill the Upper Left Skin |
| Empennage
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| Elevator
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| 1.67 hours
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Layed out the left skin and aligned the holes with the rivet lines.
Drilled and cleco'd the skin in place following the same pattern as the other skins.
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| Entry Date: Saturday, Mar 26, 2005 (details) |
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| Position and Drill the Upper Right Skin |
| Empennage
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| Elevator
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| 1.25 hours
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Flipped the entire framework and lower skin assembly (with cleco's still in) and aligned on the work table.
Clamped the right skin in place and drilled the initial rivet holes in Rib A.
Drilled, in order, the forward spar, the ribs, and the aft partial spar.
Note: all holes drilled in the top skin will be #40's since we will have full access for riveting without the bottom skins in place.
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| Entry Date: Saturday, Mar 26, 2005 (details) |
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| Position and Drill the Control Horn Attach Angles |
| Empennage
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| Elevator
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| 0.5 hours
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The control horn attach angles are rivets to Ribs A and B. Removed one set of clecos (per rib) and drew a line along the rib. Aligned and clamped the attach angles in place.
Drilled through the angle, both skins, rib, and stiffener.
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| Entry Date: Friday, Mar 25, 2005 (details) |
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| Mark and Cut the Trim Tab Pushrod Slot in the Lower Right Skin |
| Empennage
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| Elevator
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| 0.34 hours
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Used the trim cable slot already cut in the left skin to trace out the hole for the right. Removed the skins, trimmed out the second hole like the first, and deburred.
Re-cleco'd the skins on the frame.
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| Entry Date: Wednesday, Mar 23, 2005 (details) |
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| Drill the Lower Left Skin |
| Empennage
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| Elevator
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| 1 hours
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Followed the same procedures used on the right skin to drill and cleco the left.
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| Entry Date: Tuesday, Mar 22, 2005 (details) |
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| Mark and Cut the Trim Tab Pushrod Slot in the Lower Left Skin |
| Empennage
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| Elevator
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| 0.7 hours
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Measured out the two sites on the inside of the skin for the pushrod slot. Drilled both out with a 5/16" graduated bit.
Drew lines to connect the edges of both holes and trimmed the material from inbetween.
Deburred and filed.
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| Entry Date: Monday, Mar 21, 2005 (details) |
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| Position the Left Lower Skin |
| Empennage
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| Elevator
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| 0.25 hours
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Checked alignment of the lower left skin before trimming the slot for the tip rib.
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| Entry Date: Sunday, Mar 20, 2005 (details) |
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| Drill and Cleco the Lower Right Skin |
| Empennage
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| Elevator
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| 2 hours
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Drilled (forward to aft) and cleco'd the first three holes along each rib with a #40. Then drilled the remaining rib holes with a #30 for pop rivets.
Drilled the aft spar and the four holes in Ribs A & B.
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| Entry Date: Sunday, Mar 20, 2005 (details) |
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| Position the Right Lower Elevator Skin |
| Empennage
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| Elevator
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| 1 hours
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Set up the elevator assembly on the table and supported with shims. Clamped the forward spar to the table to help keep it straight.
Then clamped the skin in multiple places and aligned the pre-punched holes to the rib/spar lines.
Drilled the first holes in the skin along the forward spar.
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| Entry Date: Sunday, Mar 20, 2005 (details) |
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| Mark and Cut the Tip Rib Notches in the Lower Skins |
| Empennage
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| Elevator
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| 0.34 hours
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Marked the right skin, center-punched, drilled, and trimmed to accommodate the tip rib. After trimming, deburred and filed the edges smooth.
Followed the same procedure on the left lower skin.
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| Entry Date: Saturday, Mar 19, 2005 (details) |
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| Cleco the Ribs/Spars and Drill Rivet Holes to Final Size |
| Empennage
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| Elevator
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| 1.85 hours
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Cleco'd the ribs to the forward spar. Marked each rib to specify its location on the spar. Drilled the spar/rib holes to final size.
Cleco'd the aft partial spar to the inboard ribs and drilled the rivet holes.
Squared and drilled the end flanges of the aft partial spar.
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| Entry Date: Saturday, Mar 19, 2005 (details) |
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| Mark Rivet Lines on the Forward Spar and Ribs |
| Empennage
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| Elevator
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| 0.75 hours
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Marked the rivet lines using our homemade line tool/guide from the rudder build.
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| Entry Date: Saturday, Mar 19, 2005 (details) |
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| Finish Drilling the Attach Angles and Control Horns, Trim Attach Angles |
| Empennage
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| Elevator
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| 1.2 hours
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Stacked and cleco'd the control horns and their attach angles. Aligned the horns, clamped, aligned the assembly, and drilled the final holes.
Marked both sets to distinguish left from right.
Trimmed the indicated corners off of the attach angles. Cleaned and deburred.
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| Entry Date: Friday, Mar 18, 2005 (details) |
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| Mark and Drill Holes in the Control Horn Attach Angles |
| Empennage
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| Elevator
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| 1 hours
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Marked and center-punched the rivet holes in the attach angle/control horn.
Drilled the index holes in the attach angle and the control horns.
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| Entry Date: Friday, Mar 18, 2005 (details) |
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| Position and Drill the Rib/Control Horn Stiffeners |
| Empennage
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| Elevator
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| 0.34 hours
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Postioned the stiffeners inside their ribs, aligned, clamped, and drilled.
Left the doublers attached to the ribs with clecos.
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| Entry Date: Wednesday, Mar 16, 2005 (details) |
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| Cut the Rib/Control Horn Stiffeners and Mark Hole Locations |
| Empennage
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| Elevator
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| 0.75 hours
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Cut the horn stiffeners from angle stock to fit inside Ribs A and B.
Marked and center-punched the rivet hole locations on the stiffeners.
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| Entry Date: Monday, Mar 14, 2005 (details) |
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| Mark Hole Positions on the Forward Spar/Hinge Doublers, Position and Drill |
| Empennage
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| Elevator
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| 2.25 hours
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Drilled the sets of holes at the rib stations and used these to mark locations for additional rivets that will attach the doublers to the spar.
Positioned and drilled the doublers in place along the spar.
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| Entry Date: Monday, Mar 14, 2005 (details) |
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| Straighten and Deburr the Parts |
| Empennage
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| Elevator
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| 2 hours
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Used a square to check all ribs for squareness. Adjusted as necessary.
***NOTE: We are installing the Electric Trim Option so our construction will differ from those building with the original Manual Trim.***
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