Different Assembly technique for Rudder Trailing Edge
In a previous post I mentioned I was not happy with the Rudder Trailing Edge. There was a gap. It looked to me like I had not gotten the epoxy thin enough before it set while assembling the trailing edge. I called Vans and they told me the epoxy is not required for structural strength, its just there to help the builder keep the part aligned during assembly, making it easier to get a straight edge. I described my trailing edge and Vans told me it was fine to fly with.
I was still not happy so I decided to re-do the trailing edge. I had a plan that would allow me to assemble the trailing edge in a jig that ensured the rudder was straight, without using any epoxy. Here is an alternate way to assemble the trailing edge.
I drilled out all the rivets on my trailing edge. I bought a new wedge piece. I also bought a rivet squeezer die that I could modify. I filed the top of the die to a 10 degree angle. Most of the epoxy came out with the old wedge piece after I removed the rivets.
I then assembled the trailing edge o the angle iron per Vans standard instructions. I removed the rudder from the angle iron and I bored out every fifth cleco hole on the angle iron so that it was big enough for the modified rivet squeezer die to fit through. I fastened the angle iron to my work bench in such a position that I had assess to the bottom side of the angle iron while the rudder was assembled and clecoed to it. I then reassembled the rudder on the angle iron. I now had access to set every fifth rivet by going through the angle iron while the rudder was held by the other clecos. I used my hand squeezer on those rivets I could access. I removed the rudder after setting on-fifth of the rivets. It was very straight and the gap was much smaller. I re-installed the rudder on the angle iron, but offset a couple of holes. I now had another set of rivets I could access through the angle iron. Again, the rudder remained straight and the gap was small and consistent. In this way I partially set all the rivets in the trailing edge.
I then removed the rudder from the angle iron and used my hydraulic squeezer with the modified rivet die to completely set all the rivets equally.
Result: I still have a small gap, much smaller than before. I think if I had used this technique the first time the gap would have been even smaller. I am very happy with the Rudder Trailing edge now.