Horizontal Stabilizer work continues

I haven't been good about posting information about my progress, but fortunately I have been good about working on the horizontal stabilizer.  At this point, I'm nearly finished with the HS, so I will make an entry to reflect the things I have done.  Here are some of the tasks I have completed: 

• Notched left and right HS-702 where bends will be located (a rat tail file and a pair of aviation snips makes this a straightforward task - much easier that a unibit).  Bent tabs 6 degrees.
• Tapered front spar reinforcement pieces (HS-710 and HS-714), bent them 6 degrees, and match drilled them to HS-702.
• Clecoed left and right HS skin to understructure and match drilled all holes.
• Disassembled everything, prepped and primed spars, ribs, and skins.
• Riveted spar reinforcement bars to rear spar.
• Riveted HS skeleton.
• Began riveting ribs to skin.

First rivets

I prepped the HS411PP elevator hinge bearing, and primed with SEM primer.  Here is the procedure I use to prepare parts for priming:

• Deburr with single or double edged deburr tool
• Use emery cloth to remove any irregularities on edges or surfaces
• Scuff with maroon Scotch Brite pad
• Clean with acetone.  Following this step, part will only be handled with gloves to prevent contamination of surface.

Bearing ready to be installed in HS411PP hinge bracket

I back drilled the HS411PP bracket (only one side has the holes pre-punched) and installed the completed bearing.  I used my pneumatic squeezer to squeeze the AN470AD4-5 rivets, which turned out well.  I know some builders use -6 rivets here, but the instructions are very specific here, so I used what was specified.

Completed hinge bearing assembly

New workshop, new table

Following the move to my new workshop, I went ahead and built an EAA Chapter 1000 standard table.  As per the suggestion of a fellow builder, I constructed the table top with a two inch overhang on each side, which will allow parts to be clamped to the table if necessary.  I was very pleased with the results, and the table has turned out to be a terrific addition to the workshop.  I like the table so much, I may build another one in the future if necessary.

Rear spar work

It's been a little while since my last post.  I moved my workshop recently, and also moved into a new home.  Building should return to a more normal schedule now though, and I'm excited to see some of the empennage parts coming together.

I finished rounding the HS609PP rear spar reinforcement bars, which turned out well.  I have included a before and after picture.  After both of the 609PPs were finished, I match drilled them to the HS603PP rear spars, and placed all of the hinge brackets.  

Before (left) and after shots of HS609PP rear spar reinforcement bars

Completed HS609PPs clecoed to the HS603PP rear spars following match drilling.

Work begins on actual airplane parts

I finished the airfoil practice project, and started working on the HS609PP rear spar reinforcement bars last night.  It took a while to figure out how to effectively use the Scotch-Brite wheel in the bench grinder, which many builders had said was the most efficient tool for this process.  I was worried that it would remove material too quickly, but it really doesn't.  I had an experienced builder look at the first 609PP today during lunch, and he said it looked good.  He gave me a few pointers that really helped me with the second reinforcement bar this evening.

I removed the second wheel from my bench grinder, which was getting in the way.  I also placed a piece of duct tape over the grinding platform, which prevents marks from being made on the surface of the work after one side has been polished.  These two items really helped me make some progress.  I need to make the 1/4" radius on each of the ends, slightly round the corners of one of the bars, and then I can begin clecoing and match drilling the 609PPs to the HS603PP rear spar channel.  I look forward to that part.  I'll include some photos of the 609PPs when they are finished.

More Practice

I finished the small practice piece last night, and it turned out much better than the one I made in the SportAir workshop.  It easy to see why so many people like the pneumatic squeezer - once it's set up, it is very easy to set rivets consistently.

I don't quite have the procedure down for adjusting the pressure on the rivet gun to produce good results yet.  The pressure was too high when I was back riveting, and I ended up having to feather the trigger very lightly to avoid completely smashing the shop heads.  Fortunately, the flush rivets all turned out pretty well.  I'll work on that more this weekend.

Practice

Yesterday I organized my workshop a little more, and worked on one of my practice kits from Vans.  The new tools from PlaneTools (Isham) are working well, although I still have much to test. When my tools were shipped, a few components were left out of my order, but a call to Isham resulted in the additional tools being shipped out right away - their customer service has been really great.  I gave the pneumatic squeezer a shot, and it created really nice dimples.  I'm going to use it to drive some rivets this evening.

I ordered my rivet gun (3x) and a back rivet plate from Cleaveland Aircraft Tool, as I liked the style of rivet gun they offered a bit better, and Isham did not carry a back rivet plate.  The Cleaveland website is one of the best among the major tool houses, and they are very good about providing information about your order.  As soon as my order was shipped (the same day it was placed), I received an email with order and tracking information, which was really nice to see.  I will definitely be ordering from these two companies in the future.