back to work indeed.... details, details

Back in the shop tonight, finishing up some of the smaller details on the elevator.

Got the motivation to cut the trim tab slot out of the trailing edge of the elevator.  The plans call for a slot for almost the full length of the trailing edge.  This doesn't leave much of the trailing edge remaining done this way, so after some discussion with Ron, I decided to shorten the trim tab somewhat.

The black line on the left near the clecos is where the plans call for the trim tab extent to be. The blue line is where I decided to shorten it to.

Cutting the skin is tricky - have to be real careful not to damage the trim tab spar.  I decided to drill some pilot holes to work towards, then clean the edge up close using a Dremel tool.  It took several assemble/disasemble cycles to get it just right but it turned out nice a square.  A round file helped to round out the inside corners.

I've decided to add some trailing edge ribs on the rear elevator skin and inside the trim tab as well.  This not only supports the skin where I changed the cut, it also looks nicer and will be cleaner aerodynamically.

It took a few tries to get it right - there is no template in the plans for these, I'm making my own.  I'm happy with the fit and feel.

Next on my list of small details was drilling the trim actuator hole in the trim spar and elevtor lower skin.  The step dill was again very handy for this:

A spare 2x4 scrap with a large hole in it made a good backer for the step drill

Took the spar out of the elevator skeleton to drill the matching slot:

Back together for final fit.  The slot stays the same as the plans.  I think I might try and come up with some sort of flexible cover for the trim actuator rod hole to prevent bugs, dirt, snow or rain from getting in there.

Started the initial fit of the elevator nose skins.  These need to be in place to confirm the correct spacing between the elevator and the stab.  Happy with the fit but surprised how much of the nose skin tucks under the rear skins - but that's what the plans call for and my nose ribs are correct!

With both nose skins temporarily in place, I set the elevator against the stab again to confirm (again) the alignment of the upper and lower horns and centre hinge bracket - all good.

Forward and rear brackets drilled and added - this really stiffens up the elevator centre assembly!

Front hinge bracket - lots of A5 rivets in this assembly!

All in all a productive night.  I'm headed back to the shop in the morning to continue to knock off the small details - it all adds up!