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The first cut
The first cut. I am smiling but in fact I am scared sh..less.
Date: 09/02/2009
Views: 1334
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imm034_35
Poser
Date: 09/02/2009
Views: 1009
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imm028_29
Cutting the first cloth. First lay up was a wrinkly mess. Found out too late that you can and should pull on the fibres to smooth out wrinkles, even when it has already wetted out.
I also discover that after cutting it is best to roll up the cloth on a tube (plastic drainpipe) and after epoxying the part, carefully roll it out again. That way the cloth comes on a bit at a time and is easily corrected.
Date: 09/02/2009
Views: 1008
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imm027_28
The product. Big scare when it wouldn't lie flat on the bench. Before binning it I found out that's the way it is supposed to be..
Another tip: the manual only introduces laying up bid on plastic sheeting for flanges later in the manual, but do this right from the beginning. It's much easier and it spares no end of grief.
Date: 09/02/2009
Views: 993
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imm019_20
Using a straight edge to align the rudder hinges & cleco them into place
Date: 09/03/2009
Views: 1163
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imm018_19
All of 'em done. Careful when floxing the hinges before riveting. This epoxy gets in everywhere and has a special affinity for moving parts
Date: 09/03/2009
Views: 1608
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imm014_15
Digging out the foam at the bottom. Used a wood drill with masking tape to show the depth, drilled all over and then finished with a Dremel with a straight machining bit
Date: 09/03/2009
Views: 1105
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imm010_11
Attacking the nutplate with a power file
Date: 09/03/2009
Views: 1225
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imm009_10
Trial fitting the nutplate
Date: 09/03/2009
Views: 1061
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imm008_9
Foam cleared, first 3 plies on and ready for nutplate installation.
Note that where the flange has been removed is totally diffferent from the manual, but this is the only way that makes sense.
Date: 09/03/2009
Views: 921
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imm006_7
Riveting the anchor nuts to the nutplate. I subsequently found out that a bench press drill is indispensible. I had drilled the rivet holes by hand and there wasn't a snowball's chance that the bolts would ever line up with the nuts. Put it down to experience and ordered a new set. And bought a drill
Date: 09/03/2009
Views: 1066
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imm020_21A
Installing the (new) nutplate on the rudder
Date: 09/03/2009
Views: 1116
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