Mounting the empennage to the tail cone #3

I did not follow the directions and mount the elevators to the HS on the bench like they tell you to.  The only reason I can see they have you do that is to help stabilize the whole mess.  My HS is already mounted to the tailcone and I used straps to help keep it stable.  So now I am going to mount the elevators.

First I need to install the rod end bearings into the elevator spars. 

 I made this tool back when I built the RV-7.  It works like a dream at installing rod end bearings into nutplates.

 Detail of how it is made on the business end.

 The bearing goes in like this.  The way it is made, it puts the pressure on the outside of the bearing and not the ball which can damage these things.

 Get the bearing started in the hole and twist to the desired depth.  Easy peasy!

I installed these exactly per the plans which is 7/8" from the center of the ball hole to the face of the elevator front spar.  To make it easier, add 3/8" to that dimension and measure 1-1/4" from the top of the outside edge of the bearing assembly to the front spar face.  I used the depth gauge feature of my digital calipers to do this. 

Amazingly this worked like a treat!   The elevator counterweight ended up perfectly aligned with the HS!  No goofing around with the bearings required!

Mounting the empennage to the tail cone #2

Got started tonight by drilling the rear HS spar to the vertical spar mounting brackets.  Starting with #30 drill to get a pilot hole.

Then moving up to a long #12 drill for final hole size.

Then I deburred the holes.

And installed the hardware called out in the plans.

Then per the plans I made this wood block to go between the front spar mounting tabs.  I then clamped it to the aft deck per the plans.

Checked about a dozen times for square.  It was really close out of the box.  I only had to move it 1/32 of an inch.

Once happy I used the front spar mounting tabs to drill the aft deck and the doubler underneath it.

Then I installed the hardware called out in the plans.  No problem with edge distance here!

Other side....no edge distance issues here either.

Then I bolted on the VS front spar mounting plate.  Amazing that this is all there is holding the VS front spar on the plane.

I then match reamed the top rear spar holes to the tailcone and installed the called out hardware.

Next I match reamed the lower holes and installed the called out hardware in the upper two.

Next I had to machine countersink the bottom holes to receive a flush head structural screw.

Here are the lower hardware in place.

Next I used the rudder hinge bracket as a guide to drill a #30 pilot hole in the whole assembly.

Then I punched it up to #12 for the hardware.

Deburred both sides of the hole.  And installed the called out hardware.

Next I installed the VS front spar bolt.  It is subject to rotation so they have you use a castle nut and a bolt with a cotter pin hole.  I won't do that now since it all has to come apart anyway.

Inside shot of the rudder stop/hinge bracket hardware.  Not enough threads for me showing so I will either go with a thin washer or a longer bolt at final assembly.

A ton of work in this pic!

Mounting the empennage to the tail cone #1

 Got started today with deburring the VS to HS front spar mount.  I still can't believe that this is all there is that holds the VS's front spar to the plane.....  I also fabricated the HS stab front spar mount spacers per the plans.  I used the band saw to cut em out.

 Next I match reamed the VS front spar mount plate to the HS front spar with a #12 reamer.

Next I reamed the top bolt hole to 1/4" full size.

 Then I deburred all the holes.

 HS front spar hole deburring.

 The back side...

 Then I went ahead and started prepping for drilling the HS mount holes onto the tailcone.  I placed the HS on the tailcone with the spacers I fabricated.  I used some straps to ensure the whole thing remains level and can't fall over.

Tail Cone Riveting Part #8

I filled the bottom of the tailcone with some rigid foam that I had laying around to be able to crawl in there without damaging the parts.

 Since the bottom of the tailcone is not exactly flat, I placed the whole thing on the floor on top of another 3/4" piece of rigid foam.  This all worked very well!

 I bucked and my uncle ran the gun.

 All done!

I then crawled inside and installed the seat belt anchor point brackets.

Finally I bolted together the elevator bellcrank to the battery box/bellcrank mount.  The bolts called out are -5 in length which seem a bit long.  A -4 would work better.

Tail Cone Riveting Part #7

 Got started tonight by finishing up the aft deck area with the hardware.  I put all the hardware in but did not torque any of it.  Some of the bolts are a little short for my taste so I will either change them to the next size longer or go with thin washers where full thickness ones are called out in the plans.

This support brace had to be match drilled with the HS stab rear spar mount bars that have a pre-punched hole in them.  They have you temporarily bolt the brace down to the aft deck then match drill the hole with a 1/8" bit then drill it up to a #12.   I used a 12" bit to drill the 1/8" hole but I had to use my angle drill adapter to drill it up to #12 due to clearance issues with the drill motor.  I have a 12" #12 bit ordered so I don't have to worry about that in the future.  I know I will need it when I go to mount the HS front spar mounts to the aft deck.  Anyway I got all of the drilling complete then removed it all, deburred the holes and then touched up the primer with rattle can stuff over the AKZO.  That is why this part is darker green.  I then proceeded to rivet the brace and the doubler in place.  These rivets are not the easiest to drive due to the weird positions you have to get into to get them.  I got through it and was happy with the results.  Then the bolts go in.   Again I did not torque anything yet.

 Same area on the other side.  Those small 470AD3 rivets are a little too short but that is the longest ones Van's provides and I don't have any others.  The two green stripes are where I touched up scratches made by my angle drill adaptor.

Bolts also go into the elevator stop brace.

 This is the underside of the HS front spar mounting area/bulkhead on the co-pilot side.  I like a few more threads than this showing so I will likely change these to longer at final assembly time.

  This is the underside of the HS front spar mounting area/bulkhead on the co-pilot side.  I like a few more threads than this showing so I will likely change these to longer at final assembly time.

 This is the HS rear spar mounting area with the vertical mounting bars.  Pilot's side.  These are a good length.

  This is the HS rear spar mounting area with the vertical mounting bars.  Co-pilot's side.  These are a good length.

 This is the bolt at the elevator stop/brace, co-pilot's side.  Again a little short for me.

  This is the bolt at the elevator stop/brace, pilot's side.  Again a little short for me.

 I then cleco'ed the aft top skin onto the tailcone to get ready to rivet it on for good.