Next up... The Rudder

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 :)

After riveting, its time to place the two skins together and get this thing looking like it belongs on a plane. This is most easily done with two people, seeing that it was approx. 11pm, most of my buddies where fast asleep.  I solved this by screwing an eyebolt along the beam of the ceiling, running a string through it and lowered the top skin one row at a time.

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.

The vertical stabilizer(VS)

The building starts with the vertical stabilizer(VS).  For those of you not pilots, The stabilizers' job is to provide stability for the aircraft, to keep it flying straight. The vertical stabilizer keeps the nose of the plane from swinging from side to side, which is called yaw

The plans are designed to take you step by step through the build and as long as you follow the plans ( DON'T jump ahead! ) the build will go smoothly.  

All the pieces pulled from inventory and ready to go.

Drillin holes.. many many holes

Starting to look like something :)

All primed and ready for the skin

All said and done, I am very happy with the work.  The learning curve is very steep and not wanting to mess up is always in the back of your mind.  I'm glad Van's has you start with the VS, it is very simple and straight forward.  As you progress through the project the parts get more involved and progressively more intricate.

Picking up the EMPENNAGE/TAILCONE KIT

As you will see, I started a bit earlier than I was first planning and I'm very glad I did. This has been nothing but a blast, I wish this was something I had done years ago!  Below you will see the Vertical stabilizer (VS), rudder and the current project the Horizontal stabilizer(HS).   There has been a ton of learning with a project like this and I'm only 3 Sections into it.  

A good friend of mine and I took a short road trip from Spokane WA to Aurora, OR to the Vans Factory to pick up the EMPENNAGE/TAILCONE KIT and take a factory tour.  Van's has a very impressive set up, well organized and most, if not all employees that I met has smiles on their faces.  

Quick builds ready to be ordered and shipped

The Part that Greg is holding ( front and rear spar assembly for the VS is 11' 1.5") was the only group of parts that didn't fit into the vehicle.  We strapped it to the top and all was well with the world again :)  Thank you Van's for the extra 2x4x10 

 

Greg giving me the thumbs up that there is plenty of room for the 6 hr drive back

Email test

The garage

The very first steps in getting the garage cleaned up and organized are happening now.  The first kit will be purchased around the end of January, giving me plenty of time to get this place looking smart.  With a bit of spring cleaning and getting rid of a few things, this space will be a cozy spot to start the adventure.  Luckily the Empennage is relatively small.  I have my name on an unofficial list at the local airport ( Felts Field - KSFF) close to home and hopefully sooner that not there will be an open hanger with my name on it.

After building the classic EAA work table, I started with the Van's control surface practice project and the I pad holder that Cleveland Aircraft Tools sent with the purchase of my tools.

Being comfortable with tools but never working with aluminum or rivets, this was a really fun project that thought me how to cut, dimple, counter sink, rivet and many of the other skills that you will need to build.  No one skill is to hard by it self, but reading carefully and following directions is CRITICAL and as I see it the difference in being frustrated and being really happy with the result.  P.s. don't jump ahead of the steps :)