Rolling the Rudder

Rolling the leading edge of the rudder skins is another one of those potential problematic moments when manipulating aluminium. After reading up on other Builders' experiences, I realised this is one of those times you just have to take extra care and time. 

Step 1. Find a pole/tube of approx 1 inch diameter and tape that to the leading edge of one skin.

Step 2. Roll the pole and slowly introduce a curve into the aluminium............slowly. Do this over and over until the curve matches the templates.

Step 3. Do the same on the other skin...

...until both sheets overlap.

Step 4. Cleco the two together...

Step 5. Rivet them together..........easy!!

Riveting Rudder

Well, that's the skins riveted.....mostly.

     

I actually thought modifying the shape of the rudder counterweight was going to be a little more difficult than it was. The lead is actually very soft...

  

This is something that I'm going to regularly check I think. Not sure I like the idea of a block of lead potentially floating in that rudder cavity if those two nuts somehow come loose. Might eventually put safety wire on them.

  

Riveted the rear spar to skin rivets...

  

 

These show the rear spar shop heads...

 

 

 

 

  

Now for the trailing edge...

 



Not totally happy with the slight gap in the trailing edge which was caused by the Seamer tool slightly running off the side at the very end.

More work on the Rudder

Now that the horizontal stabiliser has be tidied up off the workbench, I thought I'd get back to the rudder and finish that off after re-doing the right skin.

The below shot is just prior to setting up to back-rivet the trailing edge. Not really looking forward to this as I've read some horror stories about not getting the trailing edge straight as this will affect how the aircraft is trimmed.

Thought I'd take some shots while it was there...