Disassembly Time

Totally disassembled both elevators to prep for deburring and priming.

More elevator skin match reaming

Match reamed the bottom skins to the elevator skeleton.

Elevator skin match reaming

Just match reamed the top skin to both elevator skeletons.

More elevator skeleton prep....

 Match reamed this little gusset on both left and right root ribs to the rear spar.
Left side.

 Right side.

 Then I cleco'ed on the outboard shear clip on both sides.

 Next the counterbalance rib assemblies go on both sides.  This is a tight fit up near the front spar.  Lots of intersecting parts.  It can only go together one way.

 Then I match reamed the counterbalance rib assemblies to the rear spars.

 Then the front spars.

 More front spar to counterbalance rib assembly holes...

  Next the top skins on both sides get cleco'ed on.

 Marking the AEX trailing edge wedge for cutting.

 Cutting the AEX trailing edge wedge with the bandsaw.

 Clecoing the trailing edge wedge.

 Next is match drilling the folded tabs.  The top skin overlaps the bottom and has a locator hole that gets drilled into the bottom skin.

 Then I match drilled the remaining two holes using the shear clip as a locator for the holes.

 Next I cleco'ed on the elevator horns on both elevators.

 And match drilled them to full #30 size using the horn as a guide.  There are two extra holes aft of the horn web that I have no idea why they are there??? There not the usual tooling holes.  It is a mystery!

Two horns all match drilled and cleco'ed on.

Elevator Skeleton Work

 Match reamed the hinge doublers to the front spar on both elevators.

 Punched out the 5/8" trim cable hole.  Make sure you drill the correct hole!  Used a unibit or step bit.

 Cleco'ed the front spar to the bottom skin on both elevators.

 Added the rib assemblies to the left elevator.

 Added the rib assemblies to the right elevator.

 Cleco'ed the rear spar to both elevators.

 Match reamed the shear clip to the rear spar and matching rib.

 Reamed the outermost holes on the rear spar to full size.

 Match reamed the rear spar to the rib assemblies.

 Match reamed the root rib to the spars.  These are #40 holes on purpose.  Do not drill to #30.

 Match reamed the front spar to the rib assemblies.

Match reamed the trim cable inspection cover doubler to the bottom skins.

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!