I decided to redo my rudder due to the trailing edge. Here is the post outlining the new rudder.
The rudder spar is essentially complete and awaits its mating to the skin. When I was ready to rivet the horn and its associated parts together, I noticed the plans had two holes that my parts did not, except for R-00917. The missing hole on the left is critical for the tie clip, the right one must be for symmetry.
No such holes for me.
Thinking I may have missed a match-drilling step in the plans, I checked back and noticed nothing. I needed those holes, so I match-drilled the holes into the spar and R-606PP using R-00917, then cleco'd on the horn to match drill it too. After deburring and spot priming (above right shows the departure of some primer since I cleco'd without a full cure), everything came together just fine.
However, the rivet lengths called out for the plans are incorrect for the horn (including its nutplate).
1/8” Rivet | ||
Rib/Spacer | 0.035 | 0.035 |
Spar | 0.035 | 0.035 |
Doubler | 0.069 | 0.069 |
Horn | 0.135 | 0.135 |
Nutplate | 0.063 | |
Additional | 0.188 | 0.188 |
Total Length | 0.461 | 0.524 |
Size (in 1/16”) | 7.376 | 8.376 |
Rounded Up | 7.5 | 8.5 |
Rounded Down | 7 | 8 |
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