Finished trim tab and rolled left elevator leading edge: 8.2 hours

The trim servo is mounted and working good. I also rolled the left leading edge. Next steps are going to be rolling the right leading edge and fitting the elevators to the horizontal stabilizer.

 

Trim servo with pushrod on access plate ready to be mounted to the underside of the left elevator.

 

Rolling...

 

Duct tape is very important stuff for this operation.

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Riveted trim tab to elevator and started on servo: 4 hours

Riveting the trim tab hinge was fairly straight forward. There were a few tight spots because of the hinge but it worked out good.

Next was on to installing the trim tab servo. Determining the location for the servo mount took a while because it needs to be perfectly lined up with the trim tab. This is another area where the builder has to locate and drill all the rivet holes. What I have found is that any part with out the computer punched rivet holes is going to take a long time.

After I drilled the holes I fine tuned some of the parts fit then deburred, cleaned and primed the parts.

I'm ready to be done with the elevators.

 

Riveting the hinge to the left elevator.

 

Trim tab riveting done!

 

Checking trim servo fit:

 

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Trim tab hinge 2.0: 3.5 hours

I got the new trim tab hinge from Aircraft Spruce cut and drilled to both the trim tab and the left elevator. I used some techniques I read about on other builder's web sites to help with this process. The new hinge fits great.

I then was able to do the final trimming, deburring and priming for the hinge pieces.

 

The dual straight edge alignment method:

 

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More trim tab: 8.9 hours

I got the trim tab spar countersunk to accept the flush rivets and fit the hinge on the bottom. I then also got the trim tab horns shaped and drilled to the trim tab skin. After that I took everything apart and prepped it for priming. I primed everything then was able to rivet everything on the bottom of the trim tab.

The problem showed up when I went to align the trim tab with the left elevator. The trailing edge of both pieces needs to line up perfectly. Unfortunately where I had drilled the piano hinge for the trim tab didn't give me enough room for the rivets on the elevator. The instructions are very vague on this process.

I spent several hours checking alignment, etc. etc. I finally decided to order a new hinge from aircraft spruce. I also did a good bit of internet research and saw how other builders were drilling the hinge. I feel like round two with the hinge will go fine.

 

Fine tuning the trim tab alignment.

 

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Trim tab part 2: 4.4 hours

The trim tab and left elevator are definitely the most complicated part of the build so far. However the trim tab is almost finished.

I made the inboard mini rib for the trim tab. I also located and drilled all the rivet holes for the mini ribs.

Another involved area was positioning and drilling the piano hinge that attaches the trim tab to the elevator. There are no computer punched holes in this.

Now I just have to countersink some holes on the trim tab spar and the tab and parts will be ready to prime.

 

Inboard mini rib turned out good. This will be covered by a small fiberglass tip.

 

Trim tab after drilling piano hinge. Next will be locating and drilling the hinge to the elevator.

 

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Trim tab 2.0 part 1: 4 hours

I got a good bit of work done on my second trim tab but it is slow going. I got the tab bent to the correct angle then cut the ears off that you would have formed the bent over edges. I then fined tuned the shape of the trim tab ends to line up with the elevator. I also got the left mini rib (aka riblet) made. It turned out good.

The right mini rib will be easier to make and install because the right side of of the trim tab will be covered by a fiberglass fairing.

I also got the left elevator counterweight bolts installed and torqued.

 

Testing fit of mini rib in trim tab:

 

 

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Left elevator riveting mostly finished: 4.3 hours

Finished the left elevator substructure. Also riveted all of the skin except where the trim tab hinge will go.

I will start trim tab version 2.0 tomorrow.

 

Coming together nicely:

 

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Started riveting left elevator: 3.5 hours

I got most of the substructure riveted together and the initial rivets on the skin.

I also spent some time reviewing the trim tab build and servo installation for when my replacement trim tab show up.

No photos today.

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Mini ribs and primer: 5 hours

I made a lot of mini ribs today and ended up with one I was happy with for the elevator skin. I then had to add rivet holes and dimple them. Then I primed the rest of the left elevator parts and skin.

I like the mini ribs versus the tab bending because it's an incremental process versus a one shot deal. I think Vans should update these parts of the kit to include computer cut prepunched mini ribs and skins.

 

Starting a mini rib on a form block:

 

The mini rib prior to trimming:

 

Mini rib in position:

 

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Bent trim tab end then started on alternate plan: 4 hours

I did several practice bends on scrap aluminum. The first was not good but after several tries they looked good.

The plans have you bending the tabs on the elevator skin first but I took the advice of other builders and worked on the trim tab first because it's a much cheaper part and I don't have any time invested in it.

I got everything clamped and did the bends. The actual bend turned out very good but unfortunately in the process of clamping the oak blocks to the skin I put a small dent in the trim tab so it's going to the scrap pile. I have also decided that I won't be doing any more of these bends because there are to many variable and chance for error.

I spent the rest of time time working on making mini ribs.

 

First bend good:

 

Second bend good, but if you look at the left end of the upper block it is to far to the left and this put a dent in the trim tab.

 

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Working on elevator and trim tab ends: 1.7 hours

I bent the trim tab to its correct angle then cleco'd it and the left elevator together so I could check the fit and figure out the best way to close out the ends of the trim tabs and the elevator where the trim tab cutout is.

I was able to measure the angle of the trailing edge and make some wood bending blocks to test the fit.

The plans have you doing a tight 90 degree bend on these little tabs to form the ends. Another option is to cut the tabs off and fabricate a small rib to go in their place.

I'm leaning towards trying the bends as per the plans. If that doesn't work out I will cut them off and make the mini ribs.

 

Left elevator and trim tab:

 

These protruding tabs have to be bent over to close out the ends on each piece ... Tricky!

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Deburring and dimpling: 4 hours

I got the skin and the under structure deburred and dimpled.

The next step is to make some precise bends on the elevator skin near the trim tab. I started research this because a lot if builders seem to have trouble with this operation.

No pictures today.

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More left elevator prep: 6 hours

I got the lead counterweight drilled then temporarily assembled the skeleton and skin and match drilled everything. I also got started deburring the spar and several other pieces.

 

There's a lot more going on with the left elevator then any piece so far.

 

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