Date | Assembly | Instruction | Part | Description | Links |
---|---|---|---|---|---|
11/20/2010 | Tail | T08 | Drilled holes on rudder drive horn using the drill press. Also deburred holes and edges. | Photos | |
12/1/2010 | Tail | T08 | "Cut a notch in a 2x4 and wrapped a 1"" pipe with duct tape to assist in bending the of the rudder drive horn. Used the arbor press to bend the drive horn." | Photos | |
12/2/2010 | Tail | T08 | Finished drilling and up drilling the holes in all the parts for the rudder drive horn. Clecoed the parts together. | Photos | |
12/3/2010 | Tail | T08 | Rivetted the rudder drive horn. I also cut the rudder skin to size and shape to fit the drive horn. | Photos | |
12/4/2010 | Tail | T08 | Laided out the location for the pilot holes on the rudder skin. | Photos | |
12/5/2010 | Tail | T08 | Started drilling holes and clecoing the rudder skin and ribs. | Photos | |
12/7/2010 | Tail | T08 | Worked on drilling holes to attach the drive horn to the skin. | Photos | |
12/8/2010 | Tail | T08 | Made template and drilled holes for rudder hinge. | Photos | |
12/9/2010 | Tail | T08 | T08-02 | Drilling and UpDrilling Holes | Photos |
12/10/2010 | Tail | T08 | T08-02 T13-02 | Debur and remove scratches and Planning Hinge drilling | Photos |
12/13/2010 | Tail | T08 | T08-02 | Drilled holes for hinge updrilled all holes started debur and clean | Photos |
12/14/2010 | Tail | T08 | T08-02 | Finished debur and cleaning. Clecoed and started riveting. | Photos |
12/15/2010 | Tail | T08 | T08-02 | Finished riveting the rudder. | Photos |
12/18/2010 | Tail | T08 | T12-01 T12-02 T12-03 | Drilled pilot holes on T12-0102. Layout and started cutout on T12-03. | Photos |
12/19/2010 | Tail | T08 | T12-03 T12-07 | T12-03 - Cut wood form bent 90 flange drilled pilot holes and debured. T12-07 - bent 35 using arbor press. | Photos |
12/20/2010 | Tail | T08 | T12-08 | T12-08 - Cut basic shape and bent 57 degree flange at end. | Photos |
12/21/2010 | Shop | T08 | Modified Manual Rivet puller for angles in tight places | Photos | |
12/22/2010 | Tail | T08 | T12-08 T12-04 T12-06 | "T12-08 - Drilled all pilot holes and deburred. T12-04 - Cut out shape cut 5 degree angles on side drilled 1"" hole using step bit on drill press and deburred all. T12-06 - Cut rough size from .063 flat stock" | Photos |
12/27/2010 | Tail | T08 | T12-06 T12-09 | Cut rought size from .063 stock. Bent angles. Filled to final size. Used drill press to drill pilot holes. | Photos |
12/28/2010 | Tail | T08 | T12-10 T12-06 T12-09 | T12-10 - Layed out Cut out Drilled pilot holes and deburred all. T12-06 and -09 - Deburred and polished all sides & holes. T12-01 - Deburred Filed sides and polished out scratches. | Photos |
12/29/2010 | Tail | T08 | T-12 T10-01 T10-02 T10-03 | Finished deburring polishing etc all T-12 parts. Started ribs T10-01 T10-02 and T10-3. Cut to length. Finished T10-01. Cut and formed 57 degree flange on T10-02. | Photos |
12/30/2010 | Tail | T08 | T10-02 | Finished rib T10-02. Formed 90 degree flange. Deburred all edges. | Photos |
12/30/2010 | Tail | T08 | T10-03 | Started forming T10-03. | Photos |
1/3/2011 | Tail | T08 | T10-03 | Finished rib T10-03. Started studying drawing T09. Looked at how parts will be assembled. | Photos |
1/4/2011 | Tail | T08 | T09-01 | Started assembly of T09-01 Main spar assembly. | Photos |
1/5/2011 | Tail | T08 | T09-01 | Used drill press with #40 to drill pilot holes for all of T09-01 main spar assembly. | Photos |
1/6/2011 | Tail | T08 | T09-01 | Updrilled all #30 holes. | Photos |
1/8/2011 | Tail | T08 | T09-02 | Drilled #40 holes in T12-08 and T12-07. Also in T12-09 clip. Clamped many of the parts together to test approximate fit. | Photos Shop-Video |
1/9/2011 | Tail | T08 | T09-02 | Drilled #40 holes in assembly with T12-10 clip. | Photos Shop-Video |
1/9/2011 | Tail | T08 | T09-02 | Up Drilled #30 holes for assembly with T12-10 clip and T12-09 clip. Found clip T12-09 was not square to assembly. Decided to fabricate a new T12-09 clip. | Photos Shop-Video |
1/9/2011 | Tail | T08 | T12-09 | Cut rought size from .063 stock. Bent angles. Filled to final size. Used drill press to drill pilot holes. | Photos Shop-Video |
1/10/2011 | Tail | T08 | T09-02 T12-09 | T12-09 - deburred cleaned polished etc. T09-02 - drilled holes for clip T12-09 to attach to T09-02. | Photos Shop-Video |
1/10/2011 | Tail | T08 | T09-02 | Cleaned polished etc all parts for T09-02. Clecoed together all parts. Riveted T09-02 per plans. | Photos Shop-Video |
1/13/2011 | Tail | T08 | T09-01 | Drilled holes for AN3-7A bolts for attachment of T12-06 clip. Drilled pilot holes for attachment of T12-05 angle and spacer to 3/32. | Photos Shop-Video |
1/14/2011 | Tail | T08 | T09-01 | Drilled holes for attachment of T12-05 angle and spacer to 3/16. Drilled remaining holes for AN3-6A Bolts to 3/16. Removed all clecos and deburred all holes and parts. Cleaned and polished etc. Reassembled with clecos ready for rivets. | Photos Shop-Video |
1/15/2011 | Tail | T08 | T09-01 | Installed rivets per plan. Inserted bolts washers and nuts per plan. Appears that AN3-6A bolts are too long. Need to investigate and resolve. None of the bolts have been tightened other than the first AN3-6A bolt. | Photos Shop-Video |
1/21/2011 | Tail | T08 | T09-01 | Check that material thickness are correct for T09-01 they are. Added a third washer to AN3-6A bolts per discussion with Kerry at Sonex. Torqued nuts for the 8 AN3-6A bolts to 23in-lbs. Installed the 2 AN3-7A bolts for clip T12-06 and torqued to 23in-lbs. Installed AN3-7A bolts for angle T12-05. Just hand tightend since the spacer will be removed. | Photos Shop-Video |
1/21/2011 | Tail | T08 | T08-01 | Started putting T08-01 assembly (vertical stabilizer frame) together. Previously had drawn plan on table. Layed parts out on table per plan. Clamped parts together and to table. Drilled all #40 pilot holes and clecoed them together. | Photos Shop-Video |
1/22/2011 | Tail | T08 | T08-01 | Located drilled #40 pilot holes and clecoed T14-04 (rib for tip) to top of assembly. Also located drilled #40 pilot holes and clecoed T10-05 (leading edge rib) to assembly. | Photos Shop-Video |
1/23/2011 | Tail | T08 | T08-01 | Drilled all #30 holes for rivets for the assembly. | Photos Shop-Video |
1/23/2011 | Tail | T08 | T08-01 | Removed all clecos. Deburred all holes. Reassembled with clecos. Riveted per plans. | Photos Shop-Video |
1/24/2011 | Tail | T08 | T08-01 | Worked on positioning the Skin T11-01 and Hinge T10-06 to the assembly | Photos Shop-Video |
1/24/2011 | Tail | T08 | T08-01 | Drilled #40 holes and clecoed Skin T11-01 (on the hinge side) and Hinge T10-06 to the assembly. | Photos Shop-Video |
1/25/2011 | Tail | T08 | T08-01 | Worked on fitting tip to assembly | Photos Shop-Video |
1/25/2011 | Tail | T08 | T08-01 | Sanded Tip and tested fit to assembly. Drilled #30 holes for skin and hinge on the hinge side of the assembly. | Photos Shop-Video |
2/14/2011 | Tail | T08 | T08-01 | Deburred holes on skin and frame on hinge side. Made alignment marks on opposite side of aft spar. These marks are aligned with holes already drilled on hingr side of aft spar. Reassembled the skin to the frame and checked alignment marks with factory pilot holes in the skin. Ready to start riveting the one side. | Photos Shop-Video |
2/15/2011 | Tail | T08 | T08-01 | Riveted port side except for top row (to allow insert of tip later). Drilled #40 holes and clecoed other side in place. | Photos Shop-Video |
2/16/2011 | Tail | T08 | T08-01 | Drilled #30 holes. Deburred all holes. Reassembled prep for riveting. | Photos Shop-Video |
2/17/2011 | Tail | T08 | T08-01 | Completed riveting all but top row of rivets. Slide tip in place and attached rudder to test fit. All appears good. Will wait to attach tip until decision is made about paint. Looks good. Feels good to have finished something that looks like it belongs on an airplane. | Photos Shop-Video |