Misc Emp items while I wait for wings

Ok, the wings didn't get here last week so hopefully I will get a call from Fed Ex on tomorrow for delivery. I ended up doing some unplanned items on the Emp Since I had some spare time. Gave me some additional fiberglass practice and also got me just that much further along.

First I closed out the HS tips with Balsa and fiberglass which ended up being easier than I expected. Working with Glass and Fiber was kind of cool since all work to date has been with aluminum. I made a template out of cardboard, then cut the balsa, then sanded it to fit smoothly. Once I test fit it, glued it in and then put reinforcement behind it. Was really happy how it turned out.

I also final drilled the center of the elevators using a bushing I found at Lowes for .58 cents.. Was quite hard final drilling through the steel on the control arms, but was able to get it done and it turned out pretty nice. No binding as the elevators move up and down.

Empennage gets set aside for now..

I finished working on the Emp for a while, wings should be here this week and I need to get ready. I was able to close out the rudder and both elevators with final rivets. I haven't closed out the Horizontal Stab or Fin yet since I will need to do some additional work with Balsa, or foam to fully close out the fairing. But for now I have a good start on it and can work on the tips during other slow parts of the build.

I also torqued all nuts on the Emp last night and played with Torque Seal for the first time. (Didn't use torque seal on the rudder, but did torque the counterbalance) I think I got this all figured out. My understanding is that you don't put the torque seal on the treads of the bolt, only the nut, washers, and back plate. I had to torque the elevator counterbalance before closing the tip since you can't reach it after words.

Still Here

Don't give up on me.. I am still here, just not making progress by leaps and bounds right now. Waiting on the wings and slowly working on items in the garage. Been so hot in Seattle these days, can't stand to be out there for more than a few minutes at a time. I am aligning the elevators on the HS, trimming some excess skin and getting ready to final drill the root ends of each Elevator.

I have to confess, the first trim Tab I but together came out with the trailing edge not square, so I am onto my second tab like so many other builders. Will get some pics of that as I get it together..

Rebekah is heading out of country in the next couple weeks so expect some fast and furious progress and lots of updates.

Left Elevator Complete

No pictures, but I have finished the left elevator and am now working on the trim Tab. I am taking it slow since the wing kit is 3 weeks out. Will get some current photos on soon. Hard to work in Seattle these days, temps are in the high 90's and central air is not common, at least not around my house...

Left Elevator Priming

Primed the left elevator skeleton last night. Next step is final assembly, keeping that trim tab in mind.

Left Elevator Trim Tab bending

OK, after much thought and preparation I bent the tabs on the left elevator that close out the rear section where the trim tab is installed. I think I got them bent perfectly, but won't be able to tell until I get the trim tab made and set into place. I also finished all the metal prep work on the skelleton and will prime in my next session. The use of the flat rivet set worked really well, I turned down the pressure and ran it along the bend softly and slowly. It flattened the edges out really well. Note to builders: The elevator is upside down in the pictures so the upper tab is folded "over" the lower tab.

Next sessions will include priming, then onto final assembly of the left Elevator.

First Cool Electronics !

OK, so I decided to order electronic elevator trim. I figured most people now go this route and plus I get to order electronics early in the build process. The kit comes with a switch and a LED Panel Indicator which is a bummer because I will have an EFIS and a stick with Trim switches on it. So If one wanted, they could probably order the RV Rivets/Install Kit and then just buy the servo from Ray Allen and do it themselves. Might save money I don't know, but for me I got it all and now have options so I guess that is OK. Anyway, look forward to playing with this a bit and putting it into my left Elevator.

Right Elevator - Complete

Over the weekend I put the final touches on the Right Elevator. Aside from the Fiberglass it is complete.. Time to order some wings.. ;-)

In the picture, it looks like I am holding up the left elevator, but actually we are looking a the bottom of the assembly, so be assured it is the right one. No trim tab here. ;-)

Left Elevator Trim Access

I ended up dimpling the nutplates, then backriveting the nutplates onto the stiffener, then backriveting the stiffener onto the Skin. I have seen on other sites where the plate/stiffener ends up warping until it is mated with the skin and in final assembly.. Dimpling the nutplates and backriveting to the plate before back riveting it to the skin made it next to perfect. Was really excited how this piece went together.

Right Elevator Final Assembly

Bekah's back and I have the camera again so will resume my updates. Lots of work on the right elevator, backriveting skins, bending with the bending brake, Skeleton assembly etc.. Went fairly straight forward and was similar to the rudder.

When I was triming the counterweight I noticed that it had an air bubble in the original mold that was about the size of a marble.. I ended up taking some of the left over lead and melted it down and poured it into the hole filling it up. You can kind of see the outline in this picture. Was suprized to see, but easily solvable problem.

Elevator Prep

Lots of work done on the elevators over the last few days, but no pics. Bekah took the camera on a horse drive in California and all I have is my I-Phone and a 12mp camera which I am too lazy to use for photos and the size is just too big for me to have fun with. So I will just talk about what I have done and get pics in as I work the left side.

I have Cut/Primed/Backriveted stiffeners to both R and L Elevators. Bent the Right Elevator skin using the home made pressbrake and ended up with a very clean edge. Excited about how that turned out. I did us a 1/8th inch dowel in the trailing edge to make sure I didn't accidentily crease the edge.

I also have completed the right elevator skeleton and match drilled the skin, so now ready to prime the skeleton and get onto final assembly with the right elevator.

Elevator - Stiffeners

No Pictures today, but I did work through all of the Elevator Skin Stiffeners. A couple hours to cut them all from Stock and then deburring the edges which is now complete. The scotchbright wheel is great on the grinder. Had the grinder running for about 30 minutes straight while deburring.. Next steps are to match drill the stiffeners to each Elevator skin. Hope to make tons of progress on the Elevators this weekend.