06-01-2011: 2.5 hrs
Worked on the root rib and left elevator horn alignment. Posted a thread on vansairforce.net, other builders observed similar situation. The fix is to bend the front flange of the root rib a little more. I did this as suggested, but this didn't make a perfect match, but is good enough. So, I clecoed all left elevator parts together and final drilled. Started deburring parts.
Bend the front flange of the root rib as suggested by other builders, this is a little over bent, but the alignment is fine, see next photo
Alignment between root rib and elevator horn looks ok with a slightly over bent front flange on the root rib
The bent is reduced a little
Alignment between the root rib and horn is not perfect, but acceptable. The lower right holes don't match perfectly, but should be ok, given there are many rivets here, and the maximum shear force on the rivet should be less than 300 lbs total (shared by 6 rivets), assuming 100 lbs load on the stick
The match drilled holes on the root rib, there is a slight out-of-round, but should be OK.
The holes between the root rib and spar are slightly mis-matched after match drilling the horn. Per instruction, these holes are match drilled before the horn is clecoed on. Special care is needed when riveting root rib and spar.
Horn is matched drilled to root rib and spar, skin and trim spar are also clecoed on for final match drill
The elevator tip to couter balance skin attaching holes are drilled to #30 size
