Slow Progress On The Tail

Hey Gang,

One step forward, two steps back...that's been my whole summer. After recovering from my back injury in time for AirVenture 2016 and having a great time, I was eager to return home to get back to work on the project. I had a really hard time with fatigue and sleepless nights due to my allergies. Most of August and September were unproductive months...I then found out I actually had Mono, of all things! I made some slow progress on the tail section during that time, but managed to get some footage and work toward some new videos. Here are a few photos of my progress, and I will hopefully have some more videos coming soon.

Horizontal Stabilizer Skin:

 

The skin itself is just over 8.5' long. I clamped a straight edge along one side, and clamped it to the bench along the other side. I then took a piece of wood, and very gently started bending the center line in. This took 2 people, and I had to keep the measured center line in the center of the curve as I bent, but it worked quite well. Not as consistent of a bend as a brake performs, but since it's a sweeping curve (27mm radius), you can do it manually.

 Horizontal Stabilizer Skin Clecoed to Bottom Surface:

I actually screwed up doing the skin...started on the wrong side! It is much easier and makes more sense to start on the top side of the stabilizer, which is flat. Then you only have to draw the skin down around the bottom end. Now, I'll have to get creative when I draw the skin down, because it has to bend up around the rib, and then down around the top surface. Funny, I looked over the construction manual several times before starting it, and still did it wrong...this is what you get when you're fatigued: stupid mistakes. On top of that, I put 5-6 smileys in the skin because I got a little too eager to form it all the way around the radius without a second set of hands. It is extremely easy to put smileys in .020...even easier in .016! Fortunately, I can work the smileys out somewhat, and they'll be in inconspicuous spots anyway. Very aggravating though! This thing isn't supposed to get wear and tear until AFTER I start flying it in the bush!

Elevator Skeleton Parts Laid Out:

Above, I've laid out the elevator skeleton parts, including the trim motor and wiring. It's amazing how simple some of these structures really are.

Elevator Center Section Drilled and Clecoed:

 

Elevator Skeleton Match-drilled & Assembled (sans control horns):

 

Well, that's it for now. I need to finish skinning the horizontal stabilizer and finish up the videos for that. Then I'll cut and bend the skins for the elevator, match drill them and then work on installing the trim system. Lots to do, but once these are done I can start the wings! I'm hoping the warm weather holds out long enough so I can get these parts primed and riveted in time to also get my wing spars assembled. They require full corrosion protection on all of the mating surfaces and exposed surfaces, and are completely solid-riveted as an assembly before you start attaching ribs and other structures. I have to completely finish the wing spar assemblies before starting wing construction. Hoping I can get that all done before the cold weather rolls in and prevents me from doing the corrosion protection, otherwise I'll have to wait until roughly May 2017 to do assembly of the spars. There's other stuff I can do during the winter, but I may actually run out of major assemblies to work on if I can't start the wings by then. Off to the shop...

Cheers!