Elevator Piano Hinges

A good habit to get into is writing on all parts what they are and anything to assist with orientation. When all the parts are sitting next to each other it's fairly easy to see how it all goes together. That however isn't always the case.

This comment might seem obvious, but you'd be surprised how simple it is to pick up the wrong part as left and right have a tendency to look almost identical with maybe a single hole difference. It's a lot easier to understand once you've done it, previously thinking - "that couldn't happen - I won't do that."

Ahhhh, yes I did.................... and you will.

Part of the journey they said.

Don't really feel like getting this wrong - better kept those fractions there until both holes were drilled.

Always very important to get hinges lined up perfectly.

I won't be rushing this section.

Starting to look pretty good.

Unfortunately, it all needs to come apart again.

Slow and easy.....

1) Make sure the centre-line drawn on the hinge is right in the centre

2) Clamp the first one with as many clamps to ensure nothing moves

3) Drill the hole

4) Cleco the hole just drilled

5) Do the same again until the end of the hinge

Take time getting this line with exactly the right offset.

This drawing looks straight forward doesn't it?

Below is what it looks like in real-life.

Unfortunately, this is the second attempt.

Fortunately, there was enough length at the other end so I had a second shot at it without having to buy more piano hinge - lucky this time.

Trim that bit off...

Below is the correct...

These next two...are not. This was the first attempt not checking I had the measurements correct prior to drilling. As these were at the other end of the piano hinge I had to use, I made sure there was no confusion - hence the crosses.

More early Elevator work

Here's the complete elevator inventory including the skins...

E-1406 & E-1407 Elevator Trim Tab...

These little foam blocks are technique Vans use to ensure the shapes of the elevator trailing edges and the trim tab are as accurate or as close to design as possible. This obviously depends on how accurate One is with the band saw.

These two are the left and right Tip Rib Assemblies.

There're a lot of holes here. Looks like fun.

Need to match drill all these now.

Lining everything up ready to assemble.

Tip ribs have been fluted but not sanded for etching just yet.

When I look at this all I see is lots of shiny little parts..........

that need to be sanded and primed.

Elevate Me!!

Well, onto the next stage we trod - The Elevator.

Here are most of the smaller parts that contribute towards the elevators. Doesn't look so bad here...

Ahhhh, that's better.....

Below is the pile of E-1008 ribs separated as per page 09-02. Nowhere near as daunting as the wing ribs are going to be. These ones are just a warm up. I can see these are going to be painful keeping together and in position. Better make sure my labelling is up to speed.

...and here they are all lined up ready to put together for the first time...

These are the shear-clips all separated as per page 09-02: step 3

More work coming up deburring, sanding etc.

Horizontal Stab almost done!!

At this point, I'd finished all the rivets except the ones holding the rear spar to allow a final inspection by our friendly CASA Rep(Steve) prior to closing the Horizontal Stabiliser for hopefully a very long time.

Inner Horizontal Flange Rivets

These rivets....I was looking forward to.

Why? .....because the pneumatic squeezer makes life so much easier. If you're squeezing rivets and you haven't purchased one yet, do  yourself a massive favour (early birthday or Xmas pressie) and get one - you need one.

Even if you're not squeezing rivets, get one anyway - it'd look great on the wall.

There was not one of these I was unhappy with - awesome!

..a short clip of the work...

More Horizontal Stabiliser rivets

Not really happy with this chubby rendition of myself - but this will be motivation to reduce my MTOW. Luckily I should have around 3-4 years up my sleeve. Either that or I figure out how to put a turbine in it.

The next photo shows one of the tabs that should be flush on the spar flange. I didn't take note why I had to remove the whole Stringer Web Assembly, but I did when re-installing it, I should've bent the tabs slightly outward again.

A small mistake that attempted to rectify using a series of different thickness specially designed pieces of rubber with a hole to fit the rivet, but just the right thickness to compress the tab and set the rivet at the same time.

The tab didn't rivet totally flush, but I was happy enough.

Below is one of the better skin rivets. 

Sorry - this one is a bit of a pose but for a Builder's log, I really don't have many photos showing me doing the building. Rocket's a good mate who's been assisting pretty much whenever I've asked. He's a good bloke who'll probably get one of the first flights......if he wants it. I may have to drag him kicking and screaming (he can be a child sometimes)

Ahhh, one side done. The edge rivets can be done later with the pneumatic squeezer - soooooo much easier.