Stripped down centre part of elevator aiming for better skin fir and to treat the stainless rivets with duralac
Derivetted centre control horns, control horn angle brackets, ribs 1, rib 1 reinforcing piece for two reasons:
Get some Duralac onto the stainless-steel rivets holding the control horns and control horn angle bracket
See if an improved right hand skin fit can be achieved with this structure disassembled (in particular the rib 1 reinforcing brackets) removed
Obtained good result, but it is clear that I have may have overdone it with the re-bending of ribs 1. Also my efforts at recreasing right hand rib 2 and possibly rib 3 make foe a slightly pinched tip of the right hand elevator skin. I also damaged the left hand control horn bracket, and on TAFs advice will replace. I have ordered several replacment parts, with the aim of purging previous efforts at re-bending parts, prior to doing a full skin fit.
Parts
1 x EL-ANG-001-L-A-0 -- elevator left control horn mount bracket (compromised by divot)
1 x EL-ANG-001-R-A-0 -- right bracket to cover against the possibility of mismatch (due to bending tolerances) between this part and its mirror, possibly made years apart
1 x EL-HBK-001-X-A-1 -- elevator centre hinge bracket (after de-riveting 4mm centre holes were seen to have expanded to the point where new rivets do not grip)
Note with the original TAF rivets there might be a hope of reusing this hinge bracket. However from
https://www.engineersedge.com/rivet_application.htm
the maximum hole size for a 4mm standard (driven, but this can be a guide for blind rivets) rivet (5/32") is 0.171" = 4.34mm. The swollen hinge hole has expanded to 4.8 x 4.5mm - too large. Meanwhile the non-swollen hole has expanded to 4.15mm, within tolerance. So the hole is too large and the hinge must be rejected.
The control horn holes are no larger than 4.05mm - within tolerance - so these can be reused.
All the holes in the spar channel and doublers are at most 4.15mm - within tolerance - so these can be reused.
1 x EL-RIB-001-R-A-0 - elevator rib 1 right - while the altered bend is ok as discussed, see above re skin fit
1 x EL-RIB-001-L-A-0 - elevator rib 1 left- same issue
1 x EL-RIB-002-R-A-0 - elevator rib 1 right - the tail of this was too fat, I reseamed, but have overdone it slightly
2 x EL-ANG-002-X-A-0 - elevator reinforcing angle (I reckon there is about a 1mm bend positioning error - I'd rather try a new self-consistent set of new parts than attempt a rebend)
The holes in the reinforcing angle are mostly 4.15mm but some reach 4.4mm, and one is elongated to 4.5mm possibily due to the match drilling process. This is out of tolerance so these parts must be replaced
Hardware
5 x HW-ANL-030-R-X-0 -- AN3 Nyloc Locknut (I have cycled the supplied items too many times)
10 x HW-RIV-454-X-X-0 -- 4 x 12 mm stainless steel rivet - to reattach hinge and control horns.
Deburred and edge smoothed right hand rear spar channel
This post is from Adam Dickson
Replace re-bent rudder lower gusset channel