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Tail
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Here
are some pictures of the work I am doing on my tail section. I started
work on it after completing the wing spars. I wanted to get more experience
with working aluminum before I tried to complete the wing. There is less
to mess-up on the tail. |
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Here
are the ribs for the tail. They are made the same way you make the wing
ribs. The only difference is that I used double stick tape to hold the
aluminum to the form block and to the crush plate. You have to make your
own form block because The Form Block Kit does not include a block for
these ribs. 3/24/99 |
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These
are the front and rear spars. 3/24/99 |
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Here
is a close up of the center of the rear spar. 3/24/99 |
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Here
is a close up of the center of the front spar. 3/24/99 |
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This
is the horizontal stabilizer frame all drilled and ready to fit the skins
to. 3/24/99 |
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Here
is how I bent the skins. I first cut the skins to shape. I then drilled
the holes along the rear edge and clecoed them together. I placed stop
blocks on the ends which would keep the 2X4 from pressing all the way to
the bench. 3/24/99 |
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This
is what the skin looks like after being pressed. The stop blocks on the
ends were 3/4" and the 2X4 was about 3" back from the bent edge. 3/24/99 |
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Here
are the skins fitted to the frame. At this point I have not drilled most
of the rivet holes in the skin. I first wanted to trace the location of
the ribs onto the skins so that when I drill the holes they will be dead
center on the ribs. 3/24/99 |
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Here
is one spot where the pilot hole on the skin just missed the back edge
of the rib. I am adding another rivet just ahead of this one to reinforce
the area. 3/24/99 |
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Here is the complete
horizontal stabilizer. 4/15/99 |
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Here are the parts
for the vertical stabilizer. The only part that was difficult was the forward
spar attach plate. To bend the 3/16" aluminum I had to clamp it in my vice
and pound like mad with a 3 lbs.. hammer. There must be a better way! 4/15/99 |
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Here is the assembled
vertical stabilizer frame. 4/15/99 |
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Here is the vertical
stabilizer skin. I bent it the same way I bent the skins for the horizontal
stabilizer. 4/15/99 |
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Here are the finished
stabilizers. 4/15/99 |
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Here are the pre-bent
control skins which I purchased from Sonex, Ltd. The ones they first
sent me were cut wrong but Sonex replaced them free of charge. 4/15/99 |
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Here is the rudder
drilled and clecoed. I left the plastic on the aluminum to help protect
it from scratches, 5/20/99 |
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Here is rib with
the control horns attached. Be careful when you cut the angle and the notches
in the rudder skin. There is a left and a right side to the rudder and
if you notch the wrong end you will have to buy a new one like I did. 5/20/99 |
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Another problem
I ran into was the rivets on the rudder skin were running into the rivets
for the bottom rib. I had to drill out the rivets on the bottom rib, install
the rivets in the skin and then reinstall the rivets in the bottom rib.
5/20/99 |
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Here is the rudder
installed on to the vertical stabilizer. 5/20/99 |
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Here is a close-up
of the rudder hinge and control horn. 5/20/99 |
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Here is another
close up of the other side. The asymmetric shape of the control horn is
because the rudder pivots on the left side of the rudder rather than the
center. 5/20/99 |
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Here is my elevator
control horn and root ribs. Getting the horn installed so that the hinge
halves on the stabilizer match up with the hinge halves on the elevators
is a bit tricky. The horn I received was about 3/16" wider that the plans
call for, but even if it was per plans, I would wait to attach it last.
11/7/99 |
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I completed the
elevators except for the root ribs. I attached the root ribs to the control
horn. I then attached the elevators to the stabilizer and installed the
hinge pins. Once the elevators were in place, I fit and drilled the root
ribs and horn. 11/7/99 |
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When I attached
the root ribs to the horn I made sure that the ribs were in the same plane
(so to speak) so that the elevator would not have a twist. 11/7/99 |
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For the trim tab,
I used MS20257P3 hinge rather than the MS20257P1 called for in the plans.
I also used CCP-32 (stainless steel) rivets rather than the MSP-32. I don't
want my tail to rust. 11/7/99 |
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 CAUTION:
This web site is in no way a publication of Sonex, Ltd. or any other corporation.
All products mentioned are not necessarily recommended for use, but are
included for informational purposes only. Builders tips and instructions
are not meant to replace the plans and instructions from Sonex, Ltd.. All
Builder's tips and instructions are presented only as a source of information
and a forum for exchange and the sharing of ideas and construction methods.
NO responsibility or liability is assumed, expressed, or implied as to
the suitability, accuracy, safety, or approval thereof. Any party using
the suggestions, ideas, instructions or examples on these pages, does so
at their own risk and discretion and without recourse against anyone. |
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All content Copyright
© 1999-2000 David Koelzer.
All rights reserved. |
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is a registered trademark of Sonex
Ltd. |
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