Vertical stabilizer alignment 15.6 hours

I decided to revisit my alignment. After I thought I had achieved good alignment when I went to install the rudder I had to back out the middle and top rod bearings to the point where I did not have enough thread engagement. I followed the directions exactly. The issue is that the hinges when aligned with a straight edge are off because the hinge lenght must not be exact. So now I have to redo my attach plate as I drilled my holes about an 1/8 inch off, not a task I am looking forward to. I will have to fabricate an new attach plate from sheet for it to work.
Three days work 1/25/17-1/27/17. Fabricated and installed new attach plate. It took me three attempts but the third plate worked. I ended up drilling the holes about 1/8″closer to the attach bolts, that’s all the room I had. The only other option would have been to replace the forward spar.

Bending angle to attach plate.

The shorter one on the right is the new plate.

Not much room between the rivet heads and the spar bars.

Just enough room for the nuts to clear the web edge.

Good rudder horn parallel gap and rod bearings now within 1.5 turns from spec.


Electrical & GMU mount: 6.5 hours

Drilled holes for ANL base and adel clamps for right power feed. Space is really tight so I decided to mount the ANL on the baggage floor rib next to the transponder access cover. It will work but not much room. Cut and installed terminals for 6 AWG wire run from ANL to battery contactor. Installed bus tie wire to contactor and began fabricating magnetmeter mount.

Various: 5.9 hours

Fabricated USB plug holder and riveted to transponder mount. Drilled hole for transponder Adel clamp mount. Ran elevator trim wiring to baggage area. Applied heat shrink to right bus power wire.

Fabricared a stainless plug for stock firewall power wire penetration. It will be held in place wih one flush rivet and fire barrier sealant. I want a more robust solution so I will be moving the penetration over in order to install a stainless firewall penetration kit.