I'm not sure why, but I got a second wind last night that lasted until 5:30am and I couldn't stop building. So I started by cutting new piano hinge to length. I went ahead and cut all the hinges out for both rudders as I plan on replacing all the hinges on the aircraft. Something about hinges sitting around for 20 plus years doesn't sit well with me dispite the extra work of replacing them, not to mention the original had binding issues. I also spent a lot of time researching different tipes and strengths of rivets and found that the much easier MSC rivets were better then the plans BSC Rivets in both tensile and shear so the rivets shown in picture 2 were replaced with MSC-43 Rivets. Ironically, the plans calls out for the use of Non-Structural rivets on the control surfaces which to me is mind blowing! However when I really thought about it, the Fiberglass is probably more prone to fail long before the rivets do which makes sense. Anyway, a rediculous amount of time went into aligning all the hinges for a bind free operation but after all was said and done they still aren't perfect. However, the slight play in the hinge halfs are now gone and the rudder moves smoothly with very little effort. I will be fully lubricating the hinge pins prior to final assembly. Next I temporarily superglued the new hidden bellhorn into the rudder after obtaining maximum rudder throw, then floxed the edges. After cure I really gave everything a tug and confirmed that the cable wasn't rubbing and full throw was achieved. I then laid up another bed of flox in 3 places, laid up the glass per plans and will wait for cure tomorrow. After confirming the cable operation was functional I superglued the conduit along the aileron channel per plans. I did NOT however lay up glass over the conduit as I want to make sure there is no interference with the ailerons first. More could be said about my 12 hours but a picture is worth....well you know ;)
