The vertical stabilizer is pretty straightforward. Van's gives an option to create a couple of lightening holes in the rear doubler. I chose not to because I wasn't sure my small drill press would handle the flycutter that well. I decided that it would be easier for me to lose 2-3 ounces compared to losing it via cutting the aluminum plate.
Total Construction Time: 24 hours
January 12, 2006 (3 hours)
Getting started on the vertical stabilizer parts while I wait for the primer to arrive. Deburred the two spars and the four ribs.
January 13, 2006 (4 hours)
Deburred the spar doubler, removed strips of plastic from along the rivet lines of the VS skin, smoothed out a short (4") crease that was in the skin, fluted the ribs, and began assembly of the rear spar. My Sanchem corrosion-proofing supplies arrived this evening.
January 14, 2006 (6 hours)
Cleco'ed all the VS parts including skins, match drilled all, deburred the skins, deburred all holes and dimpled the ribs, spars and skins and countersunk the doubler.
January 15, 2006 (6 hours)
Sanchem'ed all the HS and VS parts, excluding skins. Still need to add sealer to parts.
January 17, 2006 (1 hour)
Decided to Alodine key structural parts, in this case the two HS doublers and the two bare aluminum attachment angles. Debating spars/ribs/etc.
January 20, 2006 (3 hours)
Decided to stick with the Sanchem for all the rest of the HS and VS parts and also use it on the skins. Applied sealer to all the parts excluding the skins. I applied the conversion chemicals to the inside of the HS and VS skins.
January 21, 2006 (4 hours)
Applied sealer to the inside of the HS and VS skins. Then used a heat gun on all sealed surfaces. The two spar doublers looked worse with sealer over the Alodine, which I believe is too heavy of a coat. Removed all the Alodine on the two doublers, re-Alodine a lighter coat, and then sealed both. I'm now completely ready to start riveting the HS and VS. Started practicing riveting a little.
January 30, 2006 (2 hours)
Aaron and I riveted the rear spar assembly together, then the front spar/rib assembly, and then cleco'ed on the skin to the front spar/rib assembly.
February 1, 2006 (3 hours)
FINISHED THE VERTICAL STABILIZER!!!
