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RV-7 Construction Log
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Date:  1-9-2012
Number of Hours:  3.50
Manual Reference:  Section 6
Brief Description:  Rudder Dissassembly and Deburring

I completely dissassembled rudder, and deburred all holes and edges of all parts. I wanted to be especially careful with the skin edges since they are only 0.016 thick. That precluded my usual method of the 2" scotchbrite wheel in my straight die grinder. I was afraid that if the wheel ever grabbed, it would wad the skin up like a piece of foil.

I tried several techniques, but what seemed to work best AND fastest (for me) was to use the flat file out my needle file set and use it on the edge like a vixen file. With the skin standing up on its long edge on the workbench under the light, I could easily see the shear marks on the edge I was working as they disappeared. Usually it only took 3-5 strokes. On the short edge I stood the skin up on the mat in front my workbench so the light was on the edge. This operation left a bit of a sharp corner. On the sections where the vinyl had already been removed, I used the file again like a vixen file, but 45 degrees to the edge to knock off the corner. This only required 1-2 strokes. On the edges where there was still vinyl to protect the flat surface of the skin, I used maroon scotchbrite, which worked nicely.

When checking the rudder plan sheet to make sure I had deburred all of the rudder parts, I noticed what MAY have been the reason I had trouble fitting the counter balance skin (see Task 2 on 1/7/12). I noticed that the R-912 counterbalance rib is supposed to be installed with the web down and flanges up. I was pretty sure I had installed it upside down. I had already disassembled the rudder when I suspected the error, but I verified that I had made it by checking my Picasa Web Album from a couple of days ago. OOPS! None of the parts have elongated holes so I'm hoping I can simply turn the rib over and cleco it back together. I didn't have the time or the heart to check it tonight. :O(
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R-912 Orientation on the Plans

R-912 Orientation on the Plans

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How I Did It (Note cleco clamp holding rib flange to the skin.)

How I Did It (Note cleco clamp holding rib flange to the skin.)

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