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  #1  
Old 01-18-2015, 10:21 AM
ShortSnorter ShortSnorter is offline
 
Join Date: Dec 2013
Location: NOLA
Posts: 350
Default Great start to a bad morning...

I finished work yesterday feeling somewhat accomplished after riveting the trailing edge of the rudder successfully after I had been putting off the task for nearly a week.

I walked into the "airplane factory" this morning with two seemingly simple tasks: 1) Roll the leading edges of the rudder and 2) Pop rivet the edges together.

I got an early start this morning and drilled a few holes in my bench and installed three u bolts to hold the 3/4" conduit I planned on using to roll the skin.


The first skin rolled perfectly as planned, so I moved on to the next skin. Low and behold it rolled just as easy and I was making good time! As I starting untaping the skin from the conduit my heart stopped when I got to the top of the rudder and saw this:


I apparently I rolled the conduit too far and the u bolt was driven in to the side of the spar. I literally sat and stared breathless and speechless for at least a minute, not believing what i was seeing. Adding salt the the wound the rolled edges went together absolutely perfectly!!

I know that I'll probably have to redo the rudder but I figured I'd share and make a deposit to the "be careful of this" repository.

Maybe I'm just being optimistic, but the bend did not seem to move/affect the rivet orientation. In other words, the depth of the dent in the spar flange doesn't seem to be deep enough to affect the rivet.



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  #2  
Old 01-18-2015, 10:54 AM
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Kahuna Kahuna is offline
 
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Location: Gold Hill, NC25
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Default

I would not be building a new rudder. Seaming pliers slowly and gently to prevent cracking, will get it close to correct, then an impact flush set and a bucking bar, or tap hammer and bucking bar, will finish the job nicely. Then a little filler before paint, and your good to go.
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  #3  
Old 01-18-2015, 10:59 AM
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Mike S Mike S is offline
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Pretty sure Kahuna has it nailed, but you might want to run it by the factory just for your own peace of mind.
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  #4  
Old 01-18-2015, 11:00 AM
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wirejock wirejock is offline
 
Join Date: Oct 2005
Location: Estes Park, CO
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Default Rudder

Before you loose hope, send an e-mail to the Mother Ship. You never know.

You might consider J-bolts instead of U-bolts. On mine, I ground the end of the J-bolt to a smooth round end so it rides up and over. I still watched them to make sure but it also allows the bend to go farther till the J-bolt touched the spar web.
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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.
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  #5  
Old 01-18-2015, 12:21 PM
ShortSnorter ShortSnorter is offline
 
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Location: NOLA
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Thanks for the input, an email has been delivered to Van's. Sometimes the smallest oversight can cause major heartache!
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  #6  
Old 01-18-2015, 12:54 PM
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bddalm bddalm is offline
 
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Location: Peachtree City, Georgia
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I agree with Kahuna. Remove the fastener, straighten with seaming plier and you can route out a little of the edge to make a smooth transition. Just maintain edge distance on the fastener.
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  #7  
Old 01-18-2015, 06:11 PM
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KJBSouth KJBSouth is offline
 
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Others have encountering the same problem. You are not alone. I just finished rolling the elevators using the homemade J-bolt procedure mentioned elsewhere on the Forum. I have found it very useful to search the forums for part numbers on each step of the build. It's saved my tail several times.
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  #8  
Old 01-18-2015, 06:20 PM
DragonflyAero DragonflyAero is offline
 
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A pneumatic squeezer with flush sets in both sides might also work to flatten this out. I have used this on a number of oops occasions. Remove the rivet, flatten, redimple and then rivet. You will have to look hard to find any trace!!!!
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  #9  
Old 01-18-2015, 06:24 PM
sblack sblack is offline
 
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Location: Montreal
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I would use a plastic mallet or deadblow hammer and a dolly. Seamimg pliers will leave marks and a metal hammer will stretch the metal. The dolly could be a pc of hardwood sanded to the right radius and it could have a recess for the existing rivet. Whatever you do do it slowly and patiently. Sneak up on it, don't try to repair it in 3 blows. A half hr of gentle tapping and checking is much safer.
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  #10  
Old 01-18-2015, 08:58 PM
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ERushing ERushing is offline
 
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Ouch. I used the same method and realized just before I was about to do what you did. I got lucky.

I wrestled with that leading edge for probably 8 hours trying to get it how I wanted it (perfect.) That's the one thing in the build so far that I'm really not happy about. It'll fly. It'll be safe but it didn't turn out how I wanted it!

Good luck!
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