Complete elevator

The elevator structure was once again set up in the laser level jig, to ensure straightness.

Since the elevator was at this stage only partly skinned, and access was still available, then in view of the fact that I over-torqued the AN3 bolts previously (as I recently realised) I took the opportunity to replace the bolts and re-torque correctly, to 38 in-lbs. This went without incident. The AN3 bolts and washer were smeared with a thin coat of Duralac yellow, as usual.

The new right hand skin was rivetted in place. There were negligible issues with oil-canning, and only a slight residue of one remained present once the job was done. This was owing to the precise location of the bend, and marked contrast to the previous skin. Great support from Sling once again. Completion of the left hand skin was slightly more difficult owing to a slight bend position error, some fraction of a mm. This was enough to make oil canning an issue. I had to re-rivet in part, but with some work I was able to confine the oil canning to the bottom surface on the outer panels, and it was very slight, not an issue in practise.

The leading edge was closed without issue, with the top side edge rolled and overlapping the bottom edge. A bead of Sikaflex Pro white was used to seal the overlap.

The weights were rerivetted with Duralac yellow, and the horns edge seamed and beaded with Sikaflex Pro white. A very precise alignment was able to be achieved of all the relevant pieces.

Final laser level testing of the elevator showed it to perfectly straight.

The elevator was coupled to the horiz-stabiliser, for the first time. It assembled easily, and movement was perfectly free without binding over the full angle available. This was the result of ensuring that the HS also was perfectly straight using the laser level jig. Progress!

The fibreglass end caps remain to be rivetted in place. Some superficial patching is required as there was some areas of detachment of the gel coat from the fibreglass-resin structure. I will make an Aluminium double strip to go inside the caps, to absorb the rivet setting forces and avoid crumbling of the fibreglass material. I shaped the horn skins slightly to better fit the profile of the ribs, resulting in a perfect fit. No filling will be required.