Trevor & Dewey's RV-7 Construction Log

Empennage - Rudder

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Date: 9/11/2009
Task: Finished shaping the R-915 stiffeners, final drilled with the R-901 skins, deburred, and cut back the blue acrylic along the rivet lines. Started assembling the rudder skeleton. I purchased a piece of 3/8 MFD from Aircraft Home Depot to drill into. It worked great with clecos in the holes.

I affixed a 3M ScotchBrite wheel to a drill press for edge deburring the R-915 stiffeners. It made the process very quick. Notice the bottom where the metal has cut into the wheel. This is actually a good thing because it allows the wheel to debur all around the edges of the metal.

The stiffeners are all cut to length, shaped, and edge deburred.


Started final drilling the stiffeners to the left rudder skin.

Left side complete!

On to the right side

Right side final drilled

Cutting back the acrylic along the rivet lines.

Now the left side

Next I began to put the rudder skeleton together. I clecod R-904 bottom rib to the R-902 spar. I drilled the center hole to 3/8 using R-902 as a guide.

Next was fabricating the R-917 shim out of .032 Alclad. It was cut to 3 1/2 x 1 1/8. I clamped it to R-902, flush against R-904 and drilled the two outer holes. I then clecoed on the R-405PD rudder horn and match drilled the center hole.

Here the rudder skeleton is clecod together to check fit.