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  #1  
Old 06-11-2021, 08:44 PM
skelrad skelrad is online now
 
Join Date: Mar 2005
Location: Redmond, WA
Posts: 181
Default Trimming Stiffeners

Just working on my practice kit, but figured I'd ask the dumb question before getting to the empennage...

The plans say to trim the stiffeners by cutting to the middle of the holes punched in the angle. That leaves kind of a sharp and awkward hook on the stiffeners though. Is there a reason not to just trim so that you take out the hole completely so it's a perfectly smooth edge?
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  #2  
Old 06-11-2021, 08:46 PM
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wirejock wirejock is offline
 
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Location: Estes Park, CO
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Default Trim

Quote:
Originally Posted by skelrad View Post
Just working on my practice kit, but figured I'd ask the dumb question before getting to the empennage...

The plans say to trim the stiffeners by cutting to the middle of the holes punched in the angle. That leaves kind of a sharp and awkward hook on the stiffeners though. Is there a reason not to just trim so that you take out the hole completely so it's a perfectly smooth edge?
I hope it's ok cuz that's how I trimmed mine.
Technically I cut per instructions then filed till the sharp corners of the hole were gone.
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Estes Park, CO
wirejock at yahoo dot com
Donated 01/01/2021, plus a little extra.
RV-7A #73391, N511RV reserved (2,000+ hours)
Empennage, wings, fuse, finishing kit, now FWF
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I cannot be, nor will I be, held responsible if you try to do the same things I do and it does not work and/or causes you loss, injury, or even death in the process.

Last edited by wirejock : 06-11-2021 at 08:51 PM.
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  #3  
Old 06-11-2021, 10:45 PM
skelrad skelrad is online now
 
Join Date: Mar 2005
Location: Redmond, WA
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Default

Quote:
Originally Posted by wirejock View Post
I hope it's ok cuz that's how I trimmed mine.
Technically I cut per instructions then filed till the sharp corners of the hole were gone.
For something like stiffeners I kind of figure it’s no big deal either way, but I like to push the envelope of “there are no stupid questions.”
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  #4  
Old 06-12-2021, 05:39 AM
Jslow2 Jslow2 is online now
 
Join Date: Dec 2020
Location: Cement City
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Default

i cut mine from hole to hole then smoothed the remaining half holes on the 3m wheel.
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  #5  
Old 06-12-2021, 09:17 AM
BillL BillL is offline
 
Join Date: Sep 2007
Location: Central IL
Posts: 6,047
Default Make a go-no go wedge gauge.

I tried to make them perfect- - - - lesson learned is perfect is what fits not what my interpretation of the instructions say.

So - make a wedge the same angle as the internal rudder/elevator cavity and test the stiffeners in there. My stiffeners touched the opposite skin, so some rework was needed.
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  #6  
Old 06-12-2021, 10:28 AM
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jcarne jcarne is offline
 
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Location: Worland, Wyoming
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Default

Quote:
Originally Posted by Jslow2 View Post
i cut mine from hole to hole then smoothed the remaining half holes on the 3m wheel.
Same here.

If you don’t have a grinding wheel with a big 3M wheel you will want one.
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  #7  
Old 06-12-2021, 11:59 AM
nohoflyer nohoflyer is offline
 
Join Date: Sep 2018
Location: Brooklyn, NY
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Default

After you do two or three you will get it. Cut them per the plans then grind them to shape. I have a grinder with a metal grinder on one side and a scotchbright wheel on the other. You will use both.
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  #8  
Old 06-12-2021, 12:58 PM
Ralph Inkster Ralph Inkster is offline
 
Join Date: Feb 2008
Location: Calgary, Alberta
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Quote:
Originally Posted by nohoflyer View Post
After you do two or three you will get it. Cut them per the plans then grind them to shape. I have a grinder with a metal grinder on one side and a scotchbright wheel on the other. You will use both.
Cautionary here - Not advisable to use a stone ‘metal grinder’ with aluminum. The grinding wheel tends to melt aluminum & if that buildup on the wheel gets too hot, has the potential of exploding off in your face.
Better to do your cuts & use a bench belt sander (or sanding disc) to shape your part, than clean it up on a scotchbright wheel or deburring tool.

This & many more safety topics are the first items we cover in our Sportair courses.

Lots of Best Practices discussion on this forum lately...
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Last edited by Ralph Inkster : 06-12-2021 at 01:01 PM.
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  #9  
Old 06-12-2021, 01:06 PM
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HAL Pilot HAL Pilot is offline
 
Join Date: Nov 2015
Location: Las Vegas NV
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Default

I believe the reason they tell you to cut in the middle is so you don't accidentally remove material from the meat of a piece. I cut them then filed the left over tab even with the main piece and then deburred. The "remove" areas usually show you completely removing the tabs if you zoom in on the pictures. See enclosed.
Attached Thumbnails
Click image for larger version

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  #10  
Old 06-12-2021, 04:03 PM
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wirejock wirejock is offline
 
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Location: Estes Park, CO
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Default Grinder

Quote:
Originally Posted by nohoflyer View Post
After you do two or three you will get it. Cut them per the plans then grind them to shape. I have a grinder with a metal grinder on one side and a scotchbright wheel on the other. You will use both.
Only took one hit on my steel grinding wheel to take that off! I put a polishing wheel in it's place. Not saying it's wrong, just that I forgot it was there and caught a part on it. Had to buy a replacement. When I need to grind steel, I swap it.
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Larry Larson
Estes Park, CO
wirejock at yahoo dot com
Donated 01/01/2021, plus a little extra.
RV-7A #73391, N511RV reserved (2,000+ hours)
Empennage, wings, fuse, finishing kit, now FWF
Disclaimer
I cannot be, nor will I be, held responsible if you try to do the same things I do and it does not work and/or causes you loss, injury, or even death in the process.
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