February 27, 2007

I got down the formed AL box to get out the tail channel. Except that I already got the channel that was shipped in that box out and put it with the canopy so that it would be easy for me to get to. Unfortunately I didn't remember this until I opened the box and there was no channel in any of the control surfaces. Anyway, here's the tail channel.

It's a bit wider than the channel used for the spars, and the flanges are bent a bit more than 90 degrees.

Only 12" or so of this actually ends up in the tail - I think the rest belongs to the fuse but I don't remember now, and I don't have the plans in front of me. It might end up in the wings. I guess they needed to name the part something.

Here's the piece that goes on the v-stab. A 1" hole gets drilled in it for something - elevator control rod I think.

One edge gets a 5 degree chamfer.

Next I bent the forward spar fitting. I clamped it down to the bench with my el cheapo harbor freight clamps - this method works pretty well. I'm glad I like to overbuild work benches. To actually bend the fitting, I clamped a 2x4 to the part sticking out from the bench.

Bent to 35 degrees. I've got wood on both sides of the fitting to keep the clamps from leaving marks.

Still need to sand the edges, but its a good clean bend.

From another angle.

The bend radius as specified on the plans (thanks to my precision 2x4).

Marking the .060 for drilling before bending.

The holes drilled to #40. My base block is getting a bit holey.

Almost perfect - unfortunately I don't have laser CNC accuracy.

Clamped to the bending brake.

The HF 18" bending brake bends the AL to a good radius even with the hold down bar not having a radiused edge.

This becomes the clip that holds the forming rib to the front of the stabilizer. This is the same as the clips used on the horizontal stabilzer. I used the full size drawing to mark where to trim it.

Trimmed and marked for drilling.

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