Step 4.1, Elevator frame

The rudder frame is constructed in very nearly the same fashion as the rudder.  A main spar with ribs on the ends and stiffeners in the middle.  With the elevators, the skin is folded along the trailing edge which alleviates the need to do the double flush riveting that provided so much entertainment on the rudder.  However, the skin is not bent to the finished angle so that clearance is provided to rivet the stiffeners.  The next step after the stiffeners are attached is to bend the skins down to their finished angle.  Vans provides figure 5-7 in the build manual depicting a brake made of 2x8s.  The accompanying text is along the lines of 'build one of these to bend your skins.'  There are no dimensions or suggestion of how much to bend.  Helpfully, the build manual does provide a picture illustrating good bends and bad bends.  At the very least, I'll be able to recognize my elevator as one of the bad ones :(

I briefly considered calling the factory for guidance, but I suspect that their answer would  most likely be:  'Be careful to bend it just the right amount.'   

Besides, I don't want my file at Vans to be marked "This guy is helpless", or worse, so I think it better to just follow Vans most famous and time honored advice: It's not a rocket ship, build on!

This looks worse than it is.  It springs back.

So the squeezing wasn't quite as hard as I thought.  It looks like I got one of the good ones.  Now that the skins are squeezed, it's time to move on to the elevator frames.  This is a matter of fitting the  backing plates behind the spar in the area of the hinges (rod end bearings) and fitting the counter balance, counter balance skin and tip ribs.

Chuck came by to help out on this evening's work so we each took an elevator.  One area of difficulty was in  drilling the lead counter balances themselves.  It turns out that lead is some sticky stuff and it made the drilling much more difficult than I would have imagined.  And, I managed to get the holes off center on the counter balance rib's forward flange, but I think I will be able to properly deal with it later during final assembly.

I didn't take any pictures of the counter balance preparations, but the lead weights are first trimmed, then match drilled with the counter balance skin, and finally, counter sunk for the two retaining bolts. 

Finally, the tip assembly is partially disassembled to remove the counter balance weights and then reassembled with the spar in preparation for match drilling the skins.

The next evening, I finish the right elevator frame assembly and match drill the spar, tip ribs, elevator horn, and of course the skin.  After all that the elevator is disassembled for deburring.  

Carolina comes down to help out with the deburing and pre-priming preparations. Which is basically a light once over with a Scotch-Brite pad.

You've waited long enough.  So here it is, tonight's vacuuming action...