Thursday, April 10, 2003

Started work on the Horizontal Stabilizer. My tail kit was missing the nose ribs, so not much could be done on the HS at this time.  Drilled main ribs through forward and aft spars and cleco'd in place.  Drilled the forward spar doubler (read strengthener) in place and installed locating pins.  The locating pins are used to line up and hold the HS into the fuselage (much later in the building process)

Wednesday, July 9th, 2003 (6.5 hrs)

Having finished the Elevator yesterday, I decided to finish up the HS so I could corrosion protect all the parts at once.  Also, I'm stalling the wings until I get the wing struts which have been on backorder for some time now.  Keeping the rear spar straight was a challenge because it has quite a bow in it.  I ended up clamping a straight edge to it and checking it with my trusty laser line generator.  After I was happy with the rear spar, I set about bending the skin around the ribs.  Not easy.  The skin is quite stiff and takes quite a bit or persuasion to wrap around tightly.  To make things trickier, the skin has to be in just the right place or you'll end up with a twist in the HS.  I can see now why many builders make a special jig similar to the wing jig in order to hold the spars nice and square.  As recommended in the manual, I used a digital level with blocks on it to check the twist in the HS.  Total twist from tip to tip at the end of the day was less than 1/10th of a degree which should be OK.

Thursday, July 10th, 2003 (4.5 hrs)

Finished fitting left side skins and drilled all pilot holes.  Checking for twist frequently proved to be time consuming but worth it in the long run.  Because the left skin overlaps the right skin, there is a slight mismatch in the rivet lines on the forward and aft spars.  Also, keeping the spars straight is very important to ensure that the elevator hinge will move freely.   Installed the spar caps (whatever they do?).

Friday, September 12th, 2003 (5.5 hrs)

I was keen to get the HS finished before the movers came to pack up the kit (I'm moving back to England so the kit will have to be packed up and moved).  Riveting was pretty straight forward, made easier by the fact that the forward spar is the last to go, allowing access to the inside of the skins for holding a bucking bar.

Monday, November 10th, 2003 (3 hrs)

Unpacked HS from shipping and finished off leading edge rivets.  Pneumatic rivet squeezer worked really well here.

Tuesday, November 11th, 2003 (2.5 hrs)

Positioned and drilled holes for HS/Elevator hinge, cleaned and deburred holes and rivet together.