Elevator Counterbalance Ribs and Skins

The past few build sessions have been slowed down due to the fact that I have had to work two weeks straight with no day off.  It is maintenance shutdown week at work and they are trying to kill me.  Lots going on and I have been going wide open all week!

 Started tonight by cleco'ing together the elevator counterbalance ribs.  These parts are provided with no blue film, pre-fluted and they already have the tail ends of the long rib dimpled.  At first I thought Van's had shipped me some pre-used parts but after closer inspection, they did this work in the factory.  Not sure why.

 Match reamed these front three big holes to #12

 Then I match reamed all the #30 holes.

 Then I match reamed all these #40 holes.

That was a bunch of holes for two simple parts!

Marked the bend line on the tabs that get bent up or down on the elevator skins.

 Next I bent the tabs up and down on the elevator skins.  Used the same blocks of wood I used on the rudder counterbalance skin folding.

 And just like that I have all four tabs bent.  This locks in the position of the skins since now they are directional.

Started the Elevators!

Little bit of work tonight after cleaning up the shop and hanging the HS up in the garage.

Started by getting these ribs ready to cut apart. 

 I marked each rib to separate on a line that gets drawn from edge of notch to edge of notch.

 All the ribs marked and ready for the bandsaw.

 When ahead and marked these shear clips for separation.

 Used the bandsaw to cut the ribs apart.  There is a tiny strip of scrap on both ends.

 Here is the pile of results!

 Then I cleco'ed them together in the proper orientation.

 And reamed the holes full size on the short side of the shear clips.

 And match reamed the four rivet holes for the two rib halves.  These are now married to each other forever.

Then I marked each pair of parts that form the ribs so I can keep them together till they are riveted.  The electric pencil works great for marking!

Horizontal Stabilizer done!

Finished riveting the HS tonight!

Finished the inspar flange to skin rivets on the bottom right side.

Reinserted the rear spar into the assembly.

Blind riveted the rear spar to the inspar ribs on all the ribs except the ones on the ends of the skin that are buckable.

Inserted the snap bushings.

Easiest task in the book!

Squeezed the rear spar to inboard most inspar rib flange rivets.

Cleco'ed the rear spar flange to skin holes.  Every other hole.

Squeezed every other rivet on the rear spar flange.

Then went back and filled in the holes with the rest.

Now that is one lazer straight HS!

All finished before pulling it out of the cradles.

All finished!  Obligatory pic!

Whew!  That was a bunch of work!

Even more HS riveting....

 Today I cleco'ed all the rest of the inspar rib flanges to the skins on both sides top and bottom

 Then I riveted all the remaining holes.  Top left done.

 Top right done.

Bottom left done.