A couple of rivets at the lower rib needed to be pulled by hand as they seemed to interfere with the rivets holding the control horn. By using a hand puller I was able to ensure that the head was seated properly as I slowly pulled the rivets.
It’s been a while since I made an entry in my builders log. Work has been very slow but I am trying to get back at things and get back to recording my work. Today I was working on my rudder. I spent time deburring the ribs for inside the rudder. I found that a tongue depressor wrapped in sand paper works well to break of the burr on the inside of the flanges. After getting everything deburred, I began the riveting process. I started by riveting in the center rib then the hinge. Next, I reveted the rudder drive horn assembly. I left the drive horn assembly and the top rib off so that this area could be inspected as part of my precover inspection.
I continued working on the drive horn today. I center punched and drilled all of the pilot holes, completed the sanding and used scotch brite to clean up the part. I filed the bevel on the one edge as indicated. This appears to provide some relief when the horn is riveted to one of the ribs for the rudder.<br /><br /> With all of this work completed I started to setup for bending the drive horn.
The drive horn shown in the plans has no dimensions but is drawn full scale. I decided that the quickest way to make this part was to start with a template. I used a piece of drafting paper to trace the drive horn from the plans. I then glued the drafting paper to a piece of bristol board and cut it out. This provided a rigid template that I could trace for the final shape on the aluminum.<br /><br /> I traced the shape onto the aluminum and used the band saw to cut out the rough shape. Next, I started the sanding.