Making great progress on the Elevator with my Stepdad. We started by trimming the end of the E-00907-1 Rear Spar (11/16"), parallel to the beveled edge, with the band saw. The picture below shows the two pieces separated after cutting. The piece on the right is discarded and the Spar on the left had the edges smoothed.
Next, the E-01403 Trim Tab Hinge had to be fabricated from an AN527-P2 Piano Hinge provided in the kit. Based on the plans, each side was designated "Forward" an "Aft" for better identification later in the build. Two pilot holes had to be measured and drilled in the ends of the Trim Tab Hinge.....one hole at 3/16th & 3/16th from the edges and the second at 3/16th & 1/4th from the edges of the opposite side.
One of the E-00902-1 Front Spars needed to have a couple #30 holes....made bigger. I used a step drill to enlarge the two #30 holes to 5/8th and 3/8th.
The Front Spar (left) and Front Spar (right) were clecoed to their respective Bottom Skin. Then, the Left Elevator was assembled by using five Ribs, the Front Spar, Left Root Rib, Trim Access Reinforcement Doubler, Upper Rib, Reinforcement Doubler Brace, Rear Spar, and the Left Bottom Skin. The Right Elevator was assembled in the same fashion with the appropriate pieces.
The Gussets were then added to the assembly.....one for the left side and one for the right side and Final-Drilled #30. The one below is from the Right Elevator.
The Shear Clips were next up.....two for the left side and one for the right side. The picture below shows the Shear Clip on the Right Elevator.
Moving on to the Piano Hinge. The Hinge was separated into two individual pieces. The side previously marked "forward" was clecoed to the Rear Spar using the pilot hole that I drilled earlier. The Hinge was aligned with the top flange of the Rear Spar and clamped into place. Once in place, all the #40 holes were Match-Drilled between the Rear Spar and Piano Hinge. Below is the right side of the Piano Hinge trimmed to the edge of the Skin.
Both ends of the Piano were trimmed flush to the edges of the Trim Tab Spar.
Both Tip Ribs were clecoed to the left and right sides and top Skins for the Left and Right Elevators were then added to the assembly. Lastly, the Trailing Edge was installed, measured, and trimmed to match the Skins.
