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Jeroen Glazener Kit 615 PH-GLZ

1. In the... 2. Picking up ... 3. Chapter 1 ... 4. Chapter 2 ... 5. Chapter 3... 6. Chapter 4... 7. Chapter 6... ... 41. Upholstery

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img0520copy

img0520copy

Date: 07/28/2007 Views: 1123

Chapter 2 The Rudder

The first big lay-up.

Date: 09/02/2009
Owner: Jeroen Glazener
Size: 12 items
The first cut

The first cut

The first cut. I am smiling but in fact I am scared sh..less.

Date: 09/02/2009
Views: 2157
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imm034_35

Poser

Date: 09/02/2009
Views: 1715
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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: 1706
imm027_28

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: 1831
imm019_20

imm019_20

Using a straight edge to align the rudder hinges & cleco them into place

Date: 09/03/2009
Views: 2062
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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: 2537
imm014_15

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: 1886
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imm010_11

Attacking the nutplate with a power file

Date: 09/03/2009
Views: 2003
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imm009_10

Trial fitting the nutplate

Date: 09/03/2009
Views: 1857
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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: 1694
imm006_7

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: 1820
imm020_21A

imm020_21A

Installing the (new) nutplate on the rudder

Date: 09/03/2009
Views: 1990
Page: 1
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