Rudder/VS Tips Primed

After about 3-4 applications of microlight filler and sanding I decided to go ahead and prime the tip of the Rudder/VS. I think it turned out good enough for now, although there may have to be additional work at the time of final paint. Maybe even some additional work as I am wrapping up the project, but for now I am done and ready to reorganize the garage for the wings. This weekend will be the inventory and hopefully enough time to get started on the countersinking of the spars..

The pics show the final sanding job, and then the finished priming. I put two coats of primer on and hope I didn't get it too thick. The line between the primer and the aluminum is noticeable, hopefully it can be sanded down before final prime and paint.

Rudder/VS Final Sanding

I put 4 hours in this weekend on the VS/Rudder final sanding. It takes about as long as everyone complains about on their sites.. ;-) I started with some light weight fiberglass along the seem between the metal and the fairing (which also covered up the pop rivets nicely)to hopefully add strength and reduce any possibility of cracks in the final paint along the seam. Then mixed the West Marine System epoxy with microlight filler to start building up the low spots. Sanded, then build up the low spots again.. The pic is the filler in place after the second time I added filler. I think in this case 3rd time will be a charm. After this gets sanded down I should be just about wrapped up. I will wait on the Elevators and HS until I hit a slow spot on the wing project.

Wings Delayed - Continued fiberglass

I sent a message to Van's asking about my wings and they indicated they were delayed. I would have hoped they would tell me proactively, but they only told me in reply to my query. It seems they ran out of some skins so I should be expecting the call from FedEx this Friday or more likely next week. The two week delay is OK though because it gave me time to finish all the tips on the Emp, other than the task of filling and sanding the joints.

At this point I have all tips riveted on and the ends closed out. I may try to fill the joints at least on the Rudder and Vertical Stabilizer before the wings come. This task will take lots of time and repetition. After cleaning and scuffing all surfaces, I mix epoxy with some microlight filler which turns into a peanut butter consistency. Then like Bondo on cars, I fill any holes, joints, or gaps.. Once dry I sand, then do it again and again until I have a completely smooth contour between the Rudder tip and the Vertical Stab. Look for pics over the next few days, but as soon as the wings get here, this all stops until a later date..

Vertical Stabilizer Complete

Today I finished the VS with Rebekah's help. A few hours of riveting got the job done. Its warm in Seattle these days, was nice to work in the heat.

Now where to hang this thing...

VS Final Assembly

Final Assembly of the VS is underway. A few pics of the progress. This component goes together really fast and seems easy after the HS. Looking forward to getting moving on the rudder. A few pics below show you how I cleco in every other hole, then put the rivets into every other hole before riveting. Makes sure you don't end up with tight rivets at the end of the line. The post it tags work well for my needs.

VS Rear Spar

Started final assembly on the VS Rear Spar. This piece is going really fast. I will finish this weekend ! !

Wow, just realized no pics of this event. Will have more pics of the final assembly in the next post.

Vertical Stabilizer Priming

Today I primed the VS and started working on the rudder stiffeners. No pics of the priming because it was the same old thing. The Skin Stiffeners on the rudder was interesting. I think for this each person just has to find their own way and hopefully it is as efficient as possible. Took me a few hours to cut them all then smooth them all. I would definitely say you need a scotchbright wheel for this one and need to be good with the snips..

Vertical Stabilizer

Last night I was able to put in about 3 hours on the Vertical Stabilizer. It went together pretty fast from a skeleton/skin match drilling perspective. Got all the holes drilled and deburred and did the rib forming work. Now to dimple/countersink, then prime before final assembly. Pictures attached show the work midstream.