The rudder is the second section of the build that you get to tackle. The rudder starts off with cutting ribs, sheer clips and small angle aluminum that will act the skeleton for the rubber. The work goes fast and you will be very happy if you chose to add a band saw to the list of tools, I can't imagine cutting these angles with a hand saw.
The grayed area above shows the material you need to cut to create your new pieces. All cuts will need to be smoothed and deburred. Most of the demurring is done with either a small metal file or a 6" 3M Scotch Brite wheel.
As you can imagine building a plane in the garage is not something the rest of your family wants to miss out on. My daughter loves to play in the garage and helping any way a 3 year old can.
After clekoing all the pieces you just cut you have something that looks like this.
Skins are next. As you start putting these pieces together, you are really starting to get an idea of just how big this plane is going to be. The motorcycle in the background is a Suzuki V-strom and the vertical stabilizer is almost just as tall.
Vans has been very creative with the assembly on this rudder. After you prime the parts and start riveting the rudder for final assemble the stiffeners you cut are divided into two groups and attached to each of the corresponding sides. Back riveting is simple and fast; tape rivets in place, flip skin over and place steal pate behind the rivet line and pound away :)
Next you will be riveting the rudder spar to the sheer clips and skins to get this.
Only a few steps left. Roll the remaining skin material over it self to create a smooth surface ( as smooth as possible) and add a counter weight to the top and you are complete.
Check out my Photo bucket page for more pictures that I haven't added.
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