Sunday, October 12, 2025
Starting on the Rudder. Looks like I've got all the back-rivetted stiffeners in place, and am now about to RTFM (Read The Manual) and isolate the required parts for cleaning and work.
The Shop as It Sits Now
Back bench with angle and horizontal stab parts
The rudder, inside facing, with stiffeners in place
Looking down the length of the shop. Needs to be repainted. Meh.
R-917 Fabrication Challenges
Looking at R-917, I need to fabricate from the stock which was provided. Fortunately, I've learned that EVERYTHING with this damned thing needs to be checked online first. The stock provided is actually 3 different thicknesses. And I'm playing with parts from two different builds, split by 20 years.
Ugh.
Got out the micrometer and started working it all out. Sorted now. This is the reality of working with a kit that spans two decades—nothing can be assumed, everything must be measured, and online builder forums become your best friend.
The R-904 Disaster (and Recovery)
And then there's R-904. Learned that cutting without a back plate will rip the part. The hard way.
R-904 as it comes from the kit. That hole needs to be enlarged.
On the jig/backplate I fabricated for proper support
The underlying rib is mounted at an angle...just think it through.
The result when you use a battery drill without proper support. Not pretty.
Fortunately, I had a spare from the earlier kit. Even more fortunately, I had Ian Warburton on speed dial. One phone call, one hour later, and I had the air compressor hooked up, had looked at a few online pics showing proper technique, and managed to brace and step drill the replacement piece in six different stages using actual aircraft tools instead of a garbage battery drill.
Lessons Learned
- Use proper tools: Air drill, not battery drill, for aircraft work. The torque control and precision matter.
- Verify parts online first: When working with a kit spanning 20 years, measure everything with precision instruments. Stock thickness varies.
- Keep spare parts: Having that spare R-904 from the earlier kit saved the day. Not every mistake has a backup plan.
- Call experienced builders: Don't hesitate when stuck. Ian's advice got me past a complete work stoppage.
- Support the work: Cutting or drilling without proper backing will mangle the part. Make jigs, use backplates, take the extra time.