I made some pretty steady progress on the Rudder today. Started with removing the sharp edge on the top flange of the R-405PD Rudder Horn, then radiused the four corners.
Clecoed the R-606PP, R-607PP, R-608PP Reinforcement Plates, R-00904A-1 Bottom Rib, R-00917 Shim, and R-405PD Rudder Horn to the R-00902-1 Spar. Once clecoed, all the common holes were final drilled to #30. Then, all the parts were separated and deburred.
Radiused the forward corners and fluted the R-912 Counterbalance Rib and R-903 Top Rib flanges.
The rudder has two Skins, R-00901-R-1 and R-00901-L-1. Both Skins needed slight trimming on the top forward flange. Then, the top aft-most hole on both Skins was final drilled to #30 and dimpled to accept a CS4 flush rivet.
The left Skin flange also needed a lap joint (slight bend) to assist in making a tighter fit when the Skins are riveted to the rudder skeleton. I used the Edge Forming Tool (pictured below) from Cleaveland Aircraft Tool to make the appropriate bend. Here is the company video on how to use the tool.
Next, the Counterbalance Rib and Top Rib were clecoed to the Spar to be final drilled to #30. Then, disassembled and deburred. Finally, the E-614-020 Counterweight and Counterbalance Rib were final drilled to #12 and deburred.
