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October 27, 2004:
(0.5 hrs.) After a couple of weeks of being out of town on
business travel I was finally able to return to my project. I
managed to spend about half an hour sorting through the vertical
stabilizer(VS) parts and then cleco'ing together the rear spar.
This looks like it is going to go much faster than the horizontal
stabilizer.
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October 28, 2004: (3 hrs.) Here is a picture of the cleco'd VS skeleton. I drilled out all the spar, rib, and stiffener attach points with a #30 drill. I then took the whole thing apart, deburred the holes, smoothed the rib edges, and fluted the ribs. I then put it all back together again. |
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Next, I attached the skin and drilled out the holes on both sides. I then took the whole thing apart. |
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Here I am using a fly-cutter on my drill press to cut out the lightening holes in the VS rear spar stiffener. This is an optional step, but I figured the less weight the better. I got the fly-cutter from Sears. It seemed to do the job fairly well. It worked best to cut halfway through on on side, the flip the part over and complete the cut from the back side. This seemed to leave a cleaner cut |
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Here is the completed VS rear spar stiffener. I used a small Scotchbrite wheel on my die-grinder to cleanup the inside of the lightening holes. You can also see the lower set of rivet holes have been counter sunk for flush riveting. |