Waiex S/N W0044 Project

31st. The rest of the rudder, clecoed. After deburring, reassembly, drilling out to #30, deburring, reassembly, set rivets. One assembly done, about 40 hours invested so far, much in setting up and getting the tooling right, including switching to a 15-tpi wood blade in the band saw, which works well.

 
28th. Ordered the Wicks supplemental hardware kits and more metalworking tools early in the month. This old metal rack holds most of the formed metal parts and hardware, using retired computer backup tape boxes to hold the hardware.

 
28th. Putting the chamfer on the wing attach blocks--lots of carving metal involved in making the wing spar fittings. While waiting for the supplemental hardware kit, which contained the rudder piano hinge, worked on the rudder skin and wing spar fittings. Mismeasured both of the long lower spar stiffeners, ordered new 2.5x2.5x0.187x48 extrusion stock from Wicks to rebuild. Measure, measure, measure, then cut--after rechecking the dimensions.

 
1st. The rudder horn assembly clecoed after bending the horn. Later, riveted this assembly and cut the hinge to shape, completing the rudder detail page.

 
2nd. The rudder skin, upside down, with the cutting line marked with a laser level for the first cut of a complex shape to fit around the rudder horn. Several cuts are required to fit around the rudder horn. Used a cutoff wheel to rough cut the preformed control surface material to shape, filed to final measure line.