Originally
we planned on dimpling after priming, but I think we've decided
otherwise. For now we'll dimple then prime and see how it
goes. Here 6-3 step 7 has us dimpling the flange holes in the
ribs. Here I'm using the pop-rivet dimpler to get the nose flange
holes that I'm not able to get with the DRDT-2.
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My
original plan was to scuff all parts prior to any finishing, although
now involved with the process I was kind of curious if scuffing the
aluminum prior to Alumiprep would make much of a difference. So,
I scuffed some, but not the others. This was my first attempt at
the whole Alumiprep/Alodine process... not too bad I think... a little
boring though.
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Section
7-4 step 4 had Angela deburring the R-1002 Rudder Spar... she wasn't
too fond of the doing the lightening holes. I showed her a couple
of methods I found that worked for me when doing the Vertical
Stabilizer pieces. She tried them, and then sort of came up with
her own version. I think she still plans to experiment a bit
though...
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After
deburring the R-1002 Spar, Angela clecoed the R-1005 Rudder Horn, the
R-1007A Striker Plates, and the R-1004 Bottom Rib halves to it.
This proved to be quite challenging, as there were a (relatively) large
number of parts in a small area. Once mated it was time to final
drill the common holes.
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Unfortunately, it seems everyone
has to learn at least one thing the hard way. Well, this was our
time... The Striker Plates were proving to be quite difficult to hold
in place while drilling. They only have two holes, so that means
while you're drilling one, the plate is only being held with one
cleco. This would not work since the plate would move as soon as
the drill was powered up. So, Angela tried a few different
clamping arrangements and eventually got one to work... that is for the
Striker Plates. Well, it turns out that the R-1004 Bottom Rib
Halves were allowed to move out of position slightly. They were
on the underside, and in all the work put into the getting the Striker
Plates to stay put they were forgotten about. This resulted in
the holes being slightly out of position. This pic will be sent
to Van's tech support Monday morning just to give us the warm fuzzies
that everything is ok to proceed...
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Sheet 5 of section 7 had Angela
clecoing the R-1015 Stiffeners and the R-1010A Shear Clips to the
R-1002 Spar as well as the R-607PP & R-608PP Reinforcement
Plates. Once all together all the holes were final drilled.
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Ahhh yes... now the rudder
starts taking shape! 7-6 had Angela clecoing and final drilling
the Counterbalance Rib & the Top Rib to the top of the Spar.
Once these were done, all the internals of the rudder were in place
just begging for the skins to be put on! The next step is to
cleco the R-1006 Trailing Edge in place in order to mark it for cutting
to size. So after attaching one of the skins, the trailing edge
goes on. Tomorrow we'll mark it and get it cut.
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